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Smart Platform TM 1200

Installation and Maintenance Manual
PROPRIETARY DATA
This document contains proprietary data of ABB Industrial Systems Inc.
No disclosure, reproduction, or use of any part thereof may be made
except by written permission.
Publishing Staff:
Writers: Kay Brown, Bob Gongaware, Bill Houston, Robert Macchia, Pamela Murray
Artists: Melinda Hoyle, Kathleen Poirier
Contributors: Keith Carson, Jack Dukes, Mort Jensen, Al Luckman, Donald Stephens
© 1992, 1993, 1996, 1997, 1998 by ABB Industrial Systems Inc.

™ Smart Platform, OptiPak, and ACE are trademarks of ABB Industrial Systems Inc.
™ DESQview is a trademark of QUARTERDECK OFFICE SYSTEMS.
® Teflon is a trademark of I.E. duPont de Nemours.
® Registered trademark and service mark of ABB Industrial Systems Inc.
July 1998
101764-003
Version J
Proprietary Data: This document contains proprietary data of ABB Industrial Systems Inc. No disclosure, reproduction, or use may be made except by written permission.

Document Version History

Smart PlatformTM 1200
Installation and Maintenance Manual
Version Effective Sections Changed Sections Added Sections Deleted

Level Date by Revision by Revision by Revision
A September Original Release
1992
B January 1993 Entire Manual
C May 1993 63
D September 43
1993
E October 1993 Replacement Parts for the
ASPC Section, page 213 and
page 217
F November 1993 Entire Manual
G May 1996 Entire Manual
H September Setup Checklists, 104 Default
1996 Standardize Limits, 131-32 Compensations for
IR Moisture,
Microwave, and Ash
Sensors, 153
I June 1997 “Platform Software Setup “Ash Sensor” on
Checklist” on page 70 page 133
“Basic Tuning” on page 83
“General Information” on
page 141
“Acceptable Range for
Standardize Limits” on
page 149
“Control Panel Description”
on page 170
“Control Panel Functions” on
page 173
“Replacement Parts for the
ASPC” on page 230
J July 1998 Entire Manual
101764-003 Document Version History

Blank Page

Preface
The audience for the Smart Platform 1200 Installation and Maintenance Manual, 101764-003, is
the person(s) who initially sets up and maintains the Smart Platform 1200. The purpose of this
manual is to provide for installation, setup, and maintenance of the Smart Platform 1200.
While limited information is included, the user is expected to be somewhat familiar with operations
related to the Service Workstation and Health Reports. Additional background is available in the
documents listed below.
The following are recommended for maintenance of the Smart Platform 1200:
• Liquid Cooling Unit Reference Manual, 101333-003
• AccuRay Smart Platform System Software Manual, 101760-xxx
• AccuRay Smart Platform Troubleshooting Procedures Manual, 101761-001
• Radiation Safety Manual (for customers), 019406-001
• Specific sensor manuals
101764-003 Preface i
Blank Page

Caution and Warning Symbols

General Safety Forms and Colors
Geometric Form and Meaning
Geometric Form Meaning
Prohibition or
mandatory action
Warning
Information (including
instructions)
General Meaning of Safety Colors

Safety
color Meaning or Objective Example of Use
Red Stop Stop signs
Prohibition Emergency stops
Prohibition signs
This color is also used for fire-prevention and fire-fighting
equipment and its location
Blue1 Mandatory action Obligation to wear personal
protective equipment
Yellow Caution, risk of danger Indications of dangers,
(fire, explosion, radiation,
toxic hazards, etc.)
Warning for steps, low
passages, obstacles2
Green Safe condition Escape routes
Emergency Exits
Emergency showers
First-aid and rescue stations
1. Blue is considered a safety color only if used in a circular shape.

2. Fluorescent orange-red may be used in place of safety yellow except on safety
signs. This color is very conspicuous, especially in conditions of poor natural
lighting.
101764-003 Warning iii


Definition of Cautions and Warning Symbols

The following symbols represent warnings and cautions which you may find on the
product or in product documentation.
This symbol warns of dangerous voltage. This symbol

is used if there is a danger of a harmful or fatal shock.
This is a radiation warning and is used when ionizing

rays are present. Where a lamp is used to indicate the
presence of ionizing radiation it is red.
This is a general warning symbol and is to be used if

there is no other more specific symbol available.
This symbol warns of potential electrostatic

sensitive devices. It is used as a reminder to
observe all electrostatic discharge control
procedures.
This symbol warns of a potential crushing hazard.

For example, if the motor controller is not properly
adjusted to stall, it may be possible for someone to be
crushed between the head package and the end
column.
This symbol warns of a potential hand or

finger entrapment hazard.
iv Warning 101764-003

This symbol warns that equipment may

automatically start-up.
This symbol is a reminder that the motor must be

locked off before performing any action where
unexpected movement of the head package or any of
the associated drive elements would pose a hazard.
Note that the motor lock-out switch removes power
from only the motor controller and motor. It does
NOT remove all power from the SP.
MOTOR ONLY
This symbol is a reminder that it is mandatory to

read and understand the supporting manual before
proceeding. Additional necessary information is in
the manual.
WARNING
See WARNING text.
Exposed moving parts can

cause severe injury.
Do not operate machine
without guards in place.
Follow look out procedure
before servicing machine.
This symbol indicates the maximum

weight of an SP1200 and refers to this
manual for more information. See
Chapter 3, “Hardware Installation”.
4.5 TONS
101764-003 Warning v
Blank Page

Table of Contents
Preface ........................................................................................... i
Caution and Warning Symbols ................................................. iii
List of Figures ........................................................................... xiii
1 Product Overview..................................................................... 1
Smart Platform 1200 Options .......................................................................3
Sensor Options.......................................................................................................3
Scanner Options.....................................................................................................3
AccuRay Smart Processing Center (ASPC) Backplane
Identification ...........................................................................................4
Introduction ...........................................................................................................4
Identifying Different Backplanes ..........................................................................4
Slot Assignments ...................................................................................................5
Print Books ............................................................................................................6
12 Volt Fuses........................................................................................................6
Mechanical Structure ....................................................................................7
Way System...........................................................................................................8
Drive System .................................................................................................9
Electrical and Cable Systems ....................................................................10
Service Workstation....................................................................................12
Service Tools ...............................................................................................13
2 Radiological Safety ................................................................ 15
Safety Features ...........................................................................................16
Handling the Source ...................................................................................18
Installation of the Source ...........................................................................19
Individual Responsibility ............................................................................20
3 Hardware Installation............................................................. 23
Unpacking Instructions ..............................................................................24
Checklist ..............................................................................................................24
Handling Instructions .................................................................................25
Dimensions and Weight ......................................................................................27
Space Requirements ............................................................................................27
Safety ...........................................................................................................28
Personnel .............................................................................................................28
Machine ...............................................................................................................29
Installation Requirements ..........................................................................30
Environmental Data.............................................................................................30
Electrical Supply and Grounding Requirements .................................................30
Cabling ................................................................................................................31
Equipment Location ............................................................................................32
101764-003 Table of Contents vii


3 Hardware Installation (Continued)
Liquid Cooling Unit Setup ..........................................................................34
Pedestal Installation and Alignment..........................................................35
Installation Guidelines.........................................................................................35
Alignment of the Customer Pedestals .................................................................36
Attaching the Platform to the Pedestals ...................................................38
Platform Alignment .....................................................................................43
Carriage Alignment .....................................................................................45
Pass Angle Adjustment ..............................................................................46
Process Direction Alignment...............................................................................49
Air Gap Alignment ..............................................................................................52
Verify Air Gap ..............................................................................................53
Scan Direction Alignment...........................................................................54
4 Utility Service Installation ..................................................... 57
Air Purge ......................................................................................................58
Air and Water Supply ..................................................................................59
Electrical Hook–Up .....................................................................................61
SP1200 Power Up Procedure .....................................................................63
Starting Up the Software ............................................................................67
5 Platform Tuning...................................................................... 69
Platform Software Setup Checklist............................................................70
Motor Drive Setup (ABB ACS-100) ............................................................72
General Description.............................................................................................72
Control Panel Functions ......................................................................................72
Motor Drive Parameters ......................................................................................73
Panel Operations..................................................................................................75
Motor Controller Setup (Fincor and Lovejoy)...........................................79
Procedure.............................................................................................................79
Basic Tuning................................................................................................83
Procedure.............................................................................................................83
Head Position Setup ...................................................................................91
Notes about LHEOS and LFEOS
(Scanning Measurement Limits) ..................................................................94
Procedure for Determining Position Values........................................................95
Head Package Dimensions Setup..............................................................96
Definition of Head Package Dimensions ............................................................96
Determining and Entering the Head Dimensions................................................99
Automatic Edge-of-Sheet .........................................................................102
Setup Guidelines................................................................................................103
Entering AEOS Setup Parameters .....................................................................104
Motion Restriction Sensitivity..................................................................106
Changing the Motion Restriction Sensitivity..........................................107
Standardize Off-Sheet Delay Setup .........................................................108
viii Table of Contents 101764-003


5 Platform Tuning (Continued)
Setup Procedure.................................................................................................108
Operation Overview ..........................................................................................109
Other Host Setup Procedures ..................................................................110
6 Measurement Setup ............................................................. 111
Setup Checklists .......................................................................................112
Basis Weight Sensor Setup................................................................................112
IR Moisture Sensor Setup..................................................................................112
OptiPak Sensor Setup ........................................................................................113
Ash Sensor Setup...............................................................................................113
Gloss Sensor Setup ............................................................................................113
Apparent Density Setup.....................................................................................114
Caliper Sensor Setup .........................................................................................114
Sheet Temperature Sensor Setup.......................................................................114
Smoothness Sensor Setup..................................................................................115
Microwave Sensor Setup...................................................................................115
Smart Color Sensor Setup .................................................................................115
IR CoatWeight Sensor Setup.............................................................................115
Operation of the Sensor Health Pages....................................................116
Temperature Controller Setup
for Basis Weight, Ash, and Caliper Sensors....................................118
Smart Ash and Smart Basis Weight ..................................................................120
Temperature Controller Tuning Parameters......................................................122
Using the Optional Temperature Controller Utility ..........................................123
Setup of Customer Units ..........................................................................124
Ream Size..........................................................................................................124
Apparent Density...............................................................................................125
Changing Caliper Output Units .........................................................................125
Ash Units Setup.................................................................................................126
Enter Calibration Head Constants ...........................................................127
Basis Weight Sensor..........................................................................................127
Air Column Measurement
(Smart Basis Weight Sensor Only) ............................................................129
IR Moisture Sensor............................................................................................131
Ash Sensor.........................................................................................................133
Sheet Temperature Sensor.................................................................................135
Gloss Sensor ......................................................................................................136
Gloss Sensor Head Constant Tuning.................................................................137
Caliper Sensor ...................................................................................................139
Microwave Moisture Sensor..............................................................................140
Standardize Limits ....................................................................................141
Procedure for Changing Standardize Limits .....................................................141
General Information ..........................................................................................141
101764-003 Table of Contents ix


6 Measurement Setup (Continued)
Changing the Standardize Mode of the FCP Standardize Request ...................145
Controlling the Type of Standardize for a Specific Sensor...............................146
Smart Basis Weight Sensors..............................................................................147
Caliper Sensor ...................................................................................................148
Acceptable Range for Standardize Limits.........................................................149
Verification.................................................................................................155
Background........................................................................................................155
Phase I – Initial Static Verification ...................................................................155
Phase II – Process Measurement Verification...................................................155
Phase III – Continuing Certification..................................................................155
Implementation of the Sensor Verification Program.........................................156
Air Temperature Compensation for Basis Weight .................................157
Verification of Setup and Stability ....................................................................157
Fine Tuning ATC with dBWDT........................................................................159
Air Profile Compensation for
Basis Weight, Gloss, and Caliper......................................................161
Air Profile Data Collection................................................................................161
At the Service Workstation ...............................................................................162
At the Host Computer........................................................................................162
Enabling Air Profile Compensation ..................................................................163
Air Profile Compensation for OptiPak.....................................................164
Setup ..................................................................................................................164
Data Collection..................................................................................................165
Using the Data ...................................................................................................165
Digital Input Invert Adjustment for the Smoothness Sensor ................166
Default Compensations for IR Moisture, Microwave,
and Ash Sensors ................................................................................167
Calibrate Sample - Minimum Time Data Accumulation .........................168
7 Control Panel Operation...................................................... 169
Control Panel Description ........................................................................170
Smart Platform Modes of Operation........................................................171
Remote/On-Sheet ..............................................................................................171
Remote/Off-Sheet..............................................................................................171
Local ..................................................................................................................171
Local/Head Split................................................................................................172
Control Panel Functions...........................................................................173
Head Split Switches ..................................................................................177
8 Startup Options .................................................................... 179
Manual Startup ..........................................................................................180
Automatic Startup .....................................................................................181
Service Workstation Software Startup ....................................................182
x Table of Contents 101764-003


9 Maintenance Procedures..................................................... 183

Smart Platform Maintenance Log ............................................................184
Inspecting the Incoming Power ...............................................................186
Inspecting the Drive System ....................................................................187
Drive Belt Tension Measurement......................................................................188
Drive Belt Tension and Tip Adjustment ...........................................................189
Drive Motor Belt Inspection..............................................................................190
Drive Motor Adjustment ...................................................................................190
Seal Belt Tension Inspection .............................................................................191
Seal Belt Tension Adjustment ...........................................................................192
Head Separation and Limit Switch Inspection ..................................................193
Wheel Inspection.......................................................................................195
Platform Alignment Inspection ................................................................196
Air Purge Filter Inspection .......................................................................197
Purge Blower Replacement Process..................................................................197
Cleaning the Air Purge Filter ............................................................................198
Inspecting the Compressed Air Filters ...................................................199
Cleaning the Compressed Air Filter ..................................................................199
Inspecting the Water Filter .......................................................................200
Power and Temperature Checks..............................................................201
DC Voltage Level Checks .................................................................................202
Cabinet Environmental Checks .........................................................................202
10 Replacement Procedures .................................................... 203
Drive Motor Belt ........................................................................................204
Carriage Drive Belt ....................................................................................206
Idler Pulley .................................................................................................208
Carriage Wheel ..........................................................................................209
Seal Belt .....................................................................................................210
Split Rollers ...............................................................................................213
Flex Cable ..................................................................................................215
Electric Chassis ........................................................................................218
Electric Chassis Replacement Procedure ..........................................................218
Flex Power Cable Retrofit Kit...........................................................................220
Flex Cable Replacements ..................................................................................220
Motor Drive Replacement (ABB ACS-100) ..............................................222
Drive Motor Controller (Fincor and Lovejoy)..........................................223
Pressure Switch ........................................................................................225
Encoder ......................................................................................................226
Replacement Parts List ............................................................................227
Replacement Parts for the ASPC.............................................................230
101764-003 Table of Contents xi


11 Troubleshooting................................................................... 237
Alarm Messages ........................................................................................238
Electronics Health Report..................................................................................238
Voltage Level Out of Limits..............................................................................239
Frame Health Report .........................................................................................240
LED Interpretation .....................................................................................242
Power Supply LEDs ..........................................................................................242
ECF and ECS LEDs ..........................................................................................243
MPRC LEDs......................................................................................................244
Power Down and DC Power Analysis......................................................246
Diagnostic Card Operation.......................................................................249
Diagnostics Performed at the Sensor.................................................................250
Diagnostic Cards ...............................................................................................252
Troubleshooting Start-Up Messages.......................................................261
Appendix A: Service Workstation Activities ........................ 269
Service Workstation Setup.......................................................................270
Software.............................................................................................................270
Hardware ...........................................................................................................270
Displaying Reports ...................................................................................271
Standardize Report ............................................................................................271
Sample Check Report ........................................................................................272
Calibrate Sample Report....................................................................................273
Utilities .......................................................................................................274
The inspect Utility .............................................................................................274
The gstore Utility...............................................................................................275
Identifying Sensor Configuration ............................................................277
Determining Software Release Levels ....................................................278
Preparing On–Site Documentation..........................................................279
Index ......................................................................................... 281
xii Table of Contents 101764-003


List of Figures
Figure..................................................................................................Page
Figure 1-1 System Overview .................................................................. 2

Figure 1-2 Platform Cross Section ......................................................... 7
Figure 1-3 Carriage System .................................................................... 8
Figure 1-4 Drive System ......................................................................... 9
Figure 1-5 Electrical Component Locations ........................................... 10
Figure 2-1 Shutter Status Lights on the Lower Carriage and the
End Column ........................................................................ 17
Figure 2-2 Types of Safety Labels Used on Shipping Containers ......... 18
Figure 2-3 Safety Labels ......................................................................... 20
Figure 2-4 Safety Label for the X–ray Sensor ........................................ 21
Figure 2-5 Measurement Beam .............................................................. 22
Figure 3-1 Smart Platform on Shipping Dollies ..................................... 24
Figure 3-2 Rigging Recommendations ................................................... 26
Figure 3-3 Liquid Cooling Unit Setup .................................................... 34
Figure 3-4 Alignment of the Mounting Pedestals .................................. 36
Figure 3-5 Platform to Pedestal Installation – Drive Side ..................... 38
Figure 3-6 Platform to Pedestal Installation – Idler Side ...................... 39
Figure 3-7 Preliminary Alignment Setup ............................................... 40
Figure 3-8 Jackscrew Orientation ........................................................... 41
Figure 3-9 Verifying Platform Alignment .............................................. 43
Figure 3-10 Head Alignment Conditions ................................................. 45
Figure 3-11 Pass Angle Adjustment ......................................................... 46
Figure 3-12 Simulating the Process Pass Line ......................................... 47
Figure 3-13 Process Direction Alignment Points ..................................... 49
Figure 3-14 Upper Head Carriage ............................................................ 50
Figure 3-15 Air Gap Alignment Points .................................................... 51
Figure 3-16 Air Gap Measurement Tool .................................................. 53
Figure 3-17 Scan Direction Optimum Alignment Point ........................... 54
Figure 3-18 Scan Direction Adjustment ................................................... 55
Figure 3-19 Manual Alignment Setup ...................................................... 56
Figure 4-1 Purge Air Duct Attachment .................................................. 58
Figure 4-2 Air and Water Hookup .......................................................... 60
Figure 4-3 Standard Cable Configuration .............................................. 62
Figure 4-4 Circuit Breakers .................................................................... 63
101764-003 List of Figures xiii


Figure..................................................................................................Page
Figure 5-1 Menu Tree ............................................................................. 71

Figure 5-2 MDPanel ............................................................................... 72
Figure 5-3 Manual Servo Calibration Screen in ft. ................................ 80
Figure 5-4 Location of the Motor Controller in the Smart Platform
End Column ........................................................................ 81
Figure 5-5 Adjustments to the Motor Controller .................................... 82
Figure 5-6 Head Position Calibration – Initial Display (Example) ........ 84
Figure 5-7 Head Position Calibration Measurement .............................. 85
Figure 5-8 Head Position Calibration Screen ......................................... 86
Figure 5-9 Head Position Calibration Summary Display ....................... 87
Figure 5-10 Automatic Motor Controller Tuning Screen ......................... 89
Figure 5-11 Motor Controller Servo Calibration Summary ..................... 90
Figure 5-12 Smart Platform Positions at the Host Computer ................... 93
Figure 5-13 Limits for Multiple Frame Installations ................................ 94
Figure 5-14 Frame Health Report with Scanner Setup Panel ................... 95
Figure 5-15 Location of Head Package Measurements ............................ 98
Figure 5-16 Head Setup Using the Frame Health Report ......................... 101
Figure 5-17 Automatic Edge-of-Sheet Position Measurements ............... 103
Figure 5-18 AEOS Setup on the Frame Health Report ............................ 105
Figure 5-19 Setting Up Motion Sensitivity with the Frame
Health Report ..................................................................... 107
Figure 6-1 Example of the Health Overview Page ................................. 116
Figure 6-2 Example of Basis Weight Health Page 2 of 2
for Heater Setup ................................................................. 119
Figure 6-3 Example of the Caliper Health Report .................................. 126
Figure 6-4 Basis Weight Sensor Health Report Showing Calibration
Constants ............................................................................ 128
Figure 6-5 Air Column Measurement Health Report ............................. 129
Figure 6-6 IR Moisture Health Report Showing Calibration Constants 131
Figure 6-7 Ash Sensor Health Report ..................................................... 134
Figure 6-8 Sheet Temperature Sensor Health Report Showing
Calibration Constants ......................................................... 135
Figure 6-9 Example of Gloss Sensor Calibration Report ....................... 136
Figure 6-10 Caliper Health Report Showing Calibration Constants ........ 139
Figure 6-11 Standardize Mode Selection ................................................. 143
Figure 6-12 Basis Weight Health Report Showing Standardize
Limits ................................................................................. 147
Figure 6-13 Caliper Sensor Health Report Showing Standardize
Limits ................................................................................. 148
Figure 6-14 Heat Source for Fine Tuning dBWdT ................................... 159
xiv List of Figures 101764-003


Figure..................................................................................................Page
Figure 7-1 The Smart Platform Control Panel ........................................ 170

Figure 7-2 Locations of the Head Split Switches ................................... 177
Figure 9-1 SP1200 Lockout Switch ........................................................ 187
Figure 9-2 Drive Belt Measurement and Adjustment ............................ 189
Figure 9-3 Drive Motor Belt Check and Adjustment ............................. 190
Figure 9-4 Seal Belt Tension Checks ..................................................... 191
Figure 9-5 Seal Belt Adjustment ............................................................ 192
Figure 9-6 Head Separation Check ......................................................... 194
Figure 9-7 Electronics Health Page Report ............................................ 201
Figure 10-1 Drive Motor Belt ................................................................... 204
Figure 10-2 Clutch Assembly Details ...................................................... 205
Figure 10-3 Carriage Drive Belt ............................................................... 207
Figure 10-4 Idler Pulley ............................................................................ 208
Figure 10-5 Carriage Wheel ..................................................................... 209
Figure 10-6 Seal Belt Clamp .................................................................... 210
Figure 10-7 Seal Belt ................................................................................ 211
Figure 10-9 Seal Belt Tension Adjustments ............................................. 213
Figure 10-10 Split Roller Assembly ........................................................... 214
Figure 10-12 Carriage Assembly (Top View) ............................................ 215
Figure 10-13 Cable Suspension .................................................................. 216
Figure 10-14 Carriage Assembly ................................................................ 219
Figure 10-15 Side View of Proper Cable Dress for SP1200 ...................... 221
Figure 10-16 SP1200 Motor Drive Assembly ............................................ 222
Figure 10-17 Drive Motor Controller ......................................................... 224
Figure 10-18 Pressure Switch ..................................................................... 225
Figure 10-19 Drive End Column Parts ....................................................... 229
Figure 10-20 SP Electronics Cabinet
(086345-004 Backplane Version) ...................................... 232
Figure 10-21 SP Electronics Cabinet
(086345-003 Backplane Version) ...................................... 233
Figure 10-22 Location of SMI and BRAM Boards .................................... 234
Figure 10-23 Location of OSPS2 and EC24V ............................................ 235
Figure 11-1 Subsystem Temperature Report ............................................ 247
Figure 11-2 Historical Trend Report for Microcontroller
DC Voltages ....................................................................... 248
Figure 11-3 Test Board Hookup ............................................................... 249
Figure 11-4 Basis Weight Source Module ............................................... 251
101764-003 List of Figures xv


Figure..................................................................................................Page
Figure 11-5 Basis Weight Detector Module ............................................. 251

Figure 11-6 Sample Diagnostic Card: Top Power ................................... 253
Figure 11-7 Sample Diagnostic Card: Bottom Power ............................. 254
Figure 11-8 Sample Diagnostic Card: Top Signal ................................... 255
Figure 11-9 Sample Diagnostic Card: Bottom Signal Sensor ................. 256
Figure 11-10 Sample Diagnostic Card: Backplane Power ........................ 257
Figure 11-11 Sample Diagnostics Card: Bottom Auxiliary Power ........... 258
Figure 11-12 Sample Diagnostics Card: Detector Module ........................ 259
Figure 11-13 Sample Diagnostics Card: Source Module .......................... 260
Figure A-1 Debug Port on the Smart Platform
(-003 Backplane shown) ..................................................... 270
Figure A-2 Example of Standardize Report ............................................ 271
Figure A-3 Example of Sample Check Report ........................................ 272
Figure A-4 Example of Calibrate Sample Report ................................... 273
Figure A-5 gstore Menu Screen .............................................................. 275
xvi List of Figures 101764-003


1
Product Overview
The Smart Platform 1200 is a full size (maximum of 12 meters long), high-
performance platform for medium-to-giant size paper machines with up to 10.2
meters (402 in) of trim. The platform can carry up to seven sensors at a ± 25° pass
angle (optionally at a ± 45° pass angle). It has on-board electronics for local sensor
and platform signal processing. This chapter discusses the Smart Platform
hardware. Figure 1-1 on page 2 shows a typical Smart Platform 1200 based
measurement system.
This chapter contains the following major sections:
Section............................................................................................... Page
Smart Platform 1200 Options ........................................................................ 3
AccuRay Smart Processing Center (ASPC) Backplane Identification .......... 4
Mechanical Structure ..................................................................................... 7
Drive System ................................................................................................. 9
Electrical and Cable Systems ........................................................................ 10
Service Workstation ....................................................................................... 12
Service Tools ................................................................................................. 13
101764-003 Product Overview 1


Smart Platform 1200

Purge Blower
Process Water
Compressed
Air Liquid
Cooling Unit
Sensor(s)
Power
Transformer
(240 4-wire)
Service
Workstation
Host Computer System

(AccuRay 1180 MICRO,
AccuRay 1190, or MOD 300)
Figure 1-1 System Overview
2 Product Overview 101764-003


Smart Platform 1200 Options

The Smart Platform 1200 can be configured with the following options listed below.
Sensor Options
The following sensors can be mounted on the Smart Platform 1200.
• Basis Weight
• Infrared Moisture
• Caliper
• Ash
• OptiPakTM
• Gloss
• Temperature
• Microwave Moisture
• Edge-of-Sheet
• Smoothness
• Color
• Smart ReflectionPlus CoatWeight
Scanner Options
The following options are also available for the Smart Platform 1200.
• High temperature scanner insulation kit
• Remote electronics
• Remote control panel
• Extended end columns/extended pass angle


AccuRay Smart Processing Center (ASPC)

Backplane Identification
Introduction
With the introduction of the Smart Color sensor and the ReflectionPlus CoatWeight
sensor, it became necessary to introduce a new ASPC backplane, Part Number
086345-004. Previous updates to the ASPC backplane were all backward
compatible so there is little distinction between Part Numbers 086345-001,
086345-002, or 086345-003. The latest backplane, however, is not backward
compatible. It is important to be able to tell which backplane your scanner has.
Associated with the new backplane are new functional drawings, sensor cables, and
jumper plugs. External wiring for things like sheet break and chiller flow switches
are also different. Make sure you are using the correct documentation associated
with the particular version of backplane in your SP1200.
Identifying Different Backplanes
The most positive identification of which backplane your system uses is to locate
and read the part number tag on the PWA. The location of this tag on the 086345-
004 backplane is above the programming plug, P1. Unfortunately, on some of the
older backplanes it is on the bottom; sometimes concealed by the heat exchanger
and plumbing.
The most obvious differences in the appearances of 086345-004 backplanes with
respect to earlier versions are changes in the types of connectors (see examples of
Backplanes 086345-003 and -004 in Figure 10-20 on page 232 and Figure 10-21
on page 233).
• J8, J9, and J10 are 14-position connectors. On the earlier backplanes the
connections for sheet break, reel turn-up, chiller flow switches, etc. (J8, J9, J10,
J11, and J12) were all 10-position connectors.
• J11 is a new nine-position connector for wiring IR Sola transformers (replacing
J20 and J21); and there is not J12, J20, or J21.
• The signal programming plugs P3, P4, and P5 were changed to 64 position from
position plugs.
• The “AC IN” plug, J25 was changed to a nine-position plug from a four-position
plug.


Slot Assignments
These are the typical slot assignments for Part Number 086345-004 backplane:
Slot I.D. Function
0 ECPSR ECPSR
1 MPRC MPRC
2 0x1F ECF
3 0x21 Basis Weight
4 0x02 HemiPlus IR
5 0x03 Caliper
6 0x04 OptiPak OR Top Reflection IR
7 0x25 Dual Gloss OR Top Reflection IR
8 0x26 Ash OR Bottom Reflection IR
9 0x27 BW HAW & Microwave & Temperature & Smoothness OR
Specials
These are the typical slot assignments for Backplane Part Numbers 086345-001,
086345-002, and 086345-003:
Slot I.D. Function
0 ECPSR ECPSR
1 MPRC MPRC
2 0x1F ECF
3 0x01 Basis Weight
4 0x22 HemiPlus OR Top Reflection IR OR
Bottom Reflection IR
5 0x23 Caliper
6 0x24 OptiPak
7 0x05 Dual Gloss
8 0x06 Ash
9 0x27 Color & Microwave & Temperature OR BW HAW &
Microwave & Temperature & Smoothness OR Specials


Print Books
Because of the wiring and program jumper changes, there are two separate SP1200
print books. The print books associated with the different backplanes are:
Backplane Print Book
086345-004 101765-006
086345-003 101765-004
086345-002 101765-004
086345-001 101765-004
± 12 Volt Fuses
There are some very specific requirements in the National Electric Code (NEC)
Article 725 having to do with cable types for power-limited circuits. To increase
the selection of allowable cable types, fuses were added to the +12 Volt and -12
Volt circuits on Backplane Part Number 086345-004 for sheet break, reel turn-up,
chiller flow switches, etc. They are 5 amp fuses located between J8 and J9.


Mechanical Structure
The platform beams are constructed of custom pressed, steel box beams. The cross
section is shown in Figure 1-2.
Torsion
Box
Payload
Area
Figure 1-2 Platform Cross Section

The end columns are also made of steel box sections. The Smart Platform is welded
together in a rigid ‘‘O”. The end columns house on-platform electronics and a drive
system.
For longitudinal expansion, there is a Teflon® glide pad mounted under one end
column. The other end column is fixed.


Way System
The upper and lower sensors are carried across the web by means of a two-way
system with four wheels on each carriage. The principle of operation is shown
below.
NOTE: The encoder and drive shaft have been removed for clarity.
Figure 1-3 Carriage System

The weight of the carriage is carried on the side way bars which provide precision
of motion. The horizontal guidance is provided by contoured wheels.
The carriage wheels are made from a hard, carbon fiber and Teflon reinforced
polymer. The bearings are permanently lubricated ball bearings.
The way bars are permanently laser aligned at the factory and locked by high
strength fasteners. The side way mounting bolts are covered by self-locking plastic
push buttons.
Note: The way bar alignment is never to be adjusted in the field.


Drive System
The upper and lower carriages are traversed across the web by the drive system.
The principle of operation is shown below.
Idler
End
Encoder
Upper Drive Belt
Drive
Pulley
Idler
Pulley
Drive
Shaft
Motor
Bearing Controller
Head
Separation
Clutch Drive
Motor
Motor
Belt Tension
Adjust
Bearing
Lower Drive Belt
Drive
Pulley Idler
Pulley
Drive
End
Figure 1-4 Drive System

The drive motor is a three-phase, variable frequency AC gear motor. The motor
controller supplies the drive wave forms.
The drive belts are 2 in (50 mm) wide and made of steel-reinforced polyurethane.
A pneumatic, self-aligning head separation clutch at the middle of the drive shaft
allows for head separation.
The encoder gives a positioning pulse train consisting of A and B quadradture pulses
and an index pulse. The software counts pulses to establish the head position. A
home limit switch is used to reset the counters and establish position reference.


Electrical and Cable Systems

The major electrical components and their locations are shown below. The electrical
component descriptions are given in Table 1-1 on page 11.
Drive Idler
End IR Lamp End
Transformer Upper
Encoder Flex
Cable
AccuRay
Smart
Processing
Center
Control (ASPC)
Panel
Control
Panel
Carriage
Head PWAs AC Power
Separation Entrance
Pressure Module
Switch Sensor
Cables
Head
Separation
Head Switch
Separation
Switch Motor Limit Switch
Controller
Transformer Source Lower Bulk
Motor DC
Lockout Light Flex
Assembly Cable Supplies
Switch and IR
Limit
Switch Sola
Transformer
Motor
Controller
Figure 1-5 Electrical Component Locations


Table 1-1 Electrical Components

Item Description
AC Power Entrance Module Contains circuit breakers, filters, and the
outlet and termination for incoming AC
power
Bulk DC Supplies Delivers bulk DC voltages for the AccuRay
Smart Processing Center, sensors, and
accessories
AccuRay Smart Processing Center Contains all of the smart electronic modules
(ASPC) for platform and sensor processing,
connector systems for most of the cables,
and an environmental control system
Control Panels Allows for operation of the platform and
display status via LEDs
Limit Switch Used to stop head travel and to reset the
encoder counter
Encoder Located on the drive shaft; gives head
position feedback to the system
Motor Controller Delivers three-phase power to the drive
motor; incoming AC power is isolated via
the motor controller transformer
Head Separation Pressure Switch Located at the drive clutch assembly; it
senses the head separation to take safety
action during head split
Head Separation Switch Located on both end columns to activate
head separation clutch
Motor Lockout Switch Allows for positive lockout of power to the
drive motor for safety during maintenance
operations
IR Sola Transformer Delivers stabilized AC power to the IR
source head and lamp transformer
IR Lamp Transformer Provides for lamp power at the carriage
Carriage Connector Boards Distribute the power and signal functions
from the flex cables to the sensors
Flex Cables With signal ribbon cable, power ribbon
cable and flex hoses connect moving
carriages to end column
Sensor Cables Connect sensors to carriage connector
boards


Service Workstation
The Service Workstation is used for local interaction with the AccuRay Smart
Processing Center (ASPC). The Service Workstation can be any 386 or higher
compatible PC or lap top computer with the proper software load. For software
setup information, see the appropriate AccuRay Smart Platform System Software
Manual, 101760-xxx. The ABB MasterAid® 220 can serve as a workstation for
both the AccuRay 1190™ system and the Smart Platform.
Communication with the workstation is established via a serial port on the ASPC.
The workstation can be remoted to a computer room or used near the platform. The
connection can use RS232 for short distances or a 20MA current loop for remote
use. A current loop adapter is required at the Service Workstation to convert RS232
to a current loop.
The Service Workstation provides a set of tools that are used for monitoring, tuning,
and diagnostics of the electronics and sensors on the platform.


Service Tools
Service tools include:
• A belt tension gauge is used to set the tension in the drive belts.
• A gap setting tool is used to verify the alignment of the upper and lower heads.
• A test panel is used to access platform and sensor signals at diagnostic outlets.

Blank Page

2
Radiological Safety
This chapter is about radiological safety and the Smart Platform. The information
in this chapter is meant to be an overview and not a substitute for training and
authorization.
Section............................................................................................... Page
Safety Features .............................................................................................. 16
Handling the Source ...................................................................................... 18
Installation of the Source ............................................................................... 19
Individual Responsibility ............................................................................... 20
101764-003 Radiological Safety 15


Safety Features
The radioactive material used in the nucleonic sensors is hermetically sealed in a
high integrity metal capsule to form a sealed source. Each sealed source is
manufactured to exacting specifications and is subjected to rigorous quality control
procedures.
The sealed source in the nucleonic sensor and the X–ray tube in the X–ray sensor
are shielded because they are encased in metallic source holders and are equipped
with spring–loaded, fail–safe shutter mechanisms. The shutters are designed to
remain closed except during operation. During operation, the system applies power
to overcome the spring of the shutter mechanisms. The shutters close automatically
if power to the Smart Platform is turned off or interrupted.
When power is applied, the status of the shutters (open or closed) is indicated by
the red and green shutter lights on the Smart Platform. A red light means one or
more shutters are open and there may be a radiation beam in the measuring gap. A
green light, at the control panel on the end column, means all the shutters are fully
closed. Refer to Figure 2-1 on page 17 for a representation of the combined shutter
and status lights on the end column. The shutter status lights for each individual
shutter mechanism are located on the lower head carriage. Refer to Figure 2-1 for
the locations of the shutter status lights. The Ash High–Voltage status light (yellow)
indicates that the X–ray tube is energized when the light is illuminated.
16 Radiological Safety 101764-003


Shutter Closed Shutter Open

(Green) (Red)
Off-Sheet On-Sheet
(Amber) (Green)
Local Remote
(Amber) (Green)
Jog Reverse Jog Forward

R F
(Amber) (Amber)
Calibrate Sample Sample Check

(Amber) (Amber)
Clean Standardize Maintenance
R F Set Forward
Set Reverse
Limit Limit
SM
AR
TP
LA
TF
OR
M
Basis Weight Ash

Shutter Open Shutter Open
(Red) (Red)
Basis Weight Ash

Shutter Closed Shutter Closed
(Green) (Green)
Ash High Voltage

(Yellow)
BW ASH
Figure 2-1 Shutter Status Lights on the Lower Carriage and the End Column


Handling the Source

Only persons specifically trained in radiological safety and specifically authorized
by their controlling, regulatory agency may handle, install, or service the radiation
source, the radiation source containment, or the radiation source shielding.
Nuclear sources for the sensors are shipped to the site in a separate container which
is clearly marked with the International Radioactive Hazardous Materials shipping
label and marking statement. Refer to Figure 2-2 for a description of the labeling
and markings.
Upon receipt, the shipping container is to be placed in secure storage by an
authorized person, who is on–site and responsible for radiological safety.
The nuclear source is to remain unopened and in secure storage until a trained and
authorized person removes it for installation into the sensor.
RADIOACTIVE
CONTENTS:
ACTIVITY:
TRANSPORT INDEX
RADIOACTIVE
CONTENTS . . . . . . . . . . . . . . . . . .
7 ACTIVITY . . . . . . . . . . . . . . .
RADIOACTIVE MATERIAL, N.O.S.

UN 2982, USA DOT 7A TYPE A
RADIOACTIVE MATERIAL,
SPECIAL FORM, N.O.S.,
UN 2974, USA DOT 7A TYPE A
Figure 2-2 Types of Safety Labels Used on Shipping Containers


Installation of the Source

Installation of the radiation source may take place only after power has been turned
on to the Smart Platform and operation of all the radiological safety features has
been verified.
Only persons specifically trained in radiological safety and specifically authorized
by their controlling regulatory agency may handle, install, or service the radiation
source, the radiation source containment, or the radiation source shielding.


Individual Responsibility
All personnel are responsible for adhering to the radiological safety cautions and
procedures indicated on the labels and in the manuals that are part of the AccuRay®
1190TM Paper Machine Measurement and Control System. Refer to Figure 2-3 and
Figure 2-4 on page 21 for examples of the safety labels.
REGULATORY CONDITIONS
THE RECEIPT, POSSESSION, USE, AND TRANSFER OF
THIS DEVICE ARE SUBJECT TO A GENERAL LICENSE OR THE
EQUIVALENT AND THE REGULATIONS OF THE U.S. NRC OR A
STATE WITH WHICH THE NRC HAS ENTERED INTO AN
AGREEMENT FOR THE EXERCISE OF REGULATORY
AUTHORITY.
ABANDONMENT OR DISPOSAL PROHIBITED UNLESS
TRANSFERRED TO PERSONS SPECIFICALLY LICENSED BY
NRC OR AN AGREEMENT STATE.
OPERATION PROHIBITED IF THERE IS INDICATION OF
FAILURE OF, OR DAMAGE TO, CONTAINMENT OF RADIOACTIVE
MATERIAL.
INSTALLATION, DISMANTLING, RELOCATION, REPAIR
OR TESTING SHALL BE PERFORMED BY PERSONS
SPECIFICALLY LICENSED BY NRC OR AN AGREEMENT STATE.
DEVICE SHALL BE TESTED FOR LEAKAGE OF
RADIOACTIVE MATERIAL AND PROPER FUNCTIONING OF THE
ON–OFF MECHANISM AND INDICATOR, IF ANY, AT INTERVALS
SPECIFIED ON THE ATTACHED YELLOW LABEL.
35715REMOVAL OF THIS LABEL IS PROHIBITED
CAUTION
RADIOACTIVE MATERIAL
MODEL____________________
___________________________
DATE MEAS.________________
TEST INTERVAL______________
REMOVAL OF THIS LABEL PROHIBITED

DO NOT CONTINUOUSLY OCCUPY THE
AREA WITHIN OF THIS DEVICE
Figure 2-3 Safety Labels


CAUTION
RADIATION WHEN ENERGIZED
MODEL_______________
VOLTAGE______________
CURRENT_____________
______________________
__
REMOVAL OF THIS LABEL PROHIBITED

DO NOT CONTINUALLY OCCUPY THE
AREA WITHIN OF THIS DEVICE
WHEN ENERGIZED.
Figure 2-4 Safety Label for the X–ray Sensor

Individual responsibility also includes the following precautions:
• Pre–planning work activities to keep radiation exposure to a minimum.
• Determining that the sensor shutters are closed by looking at the status lights
before beginning work near the sensor carriage.
Never put any part of the human body in the sensor

measuring gap when the shutter is open. Refer to Figure
2-5 on page 22.


Sensor Measurement Beam
Figure 2-5 Measurement Beam

• Maintaining the safety labels and safety features.
• Not using a sensor until the safety features are functioning properly.


3
Hardware Installation
Hardware Installation guides you from the arrival of the Smart Platform on–site to
alignment of the head package assembly.
Section............................................................................................... Page
Unpacking Instructions .................................................................................. 24
Handling Instructions .................................................................................... 25
Safety ............................................................................................................. 28
Installation Requirements .............................................................................. 30
Liquid Cooling Unit Setup ............................................................................ 34
Pedestal Installation and Alignment .............................................................. 35
Attaching the Platform to the Pedestals ........................................................ 38
Platform Alignment ....................................................................................... 43
Carriage Alignment ....................................................................................... 45
Pass Angle Adjustment .................................................................................. 46
Verify Air Gap ............................................................................................... 53
Scan Direction Alignment ............................................................................. 54
101764-003 Hardware Installation 23


Unpacking Instructions
The Smart Platform is carefully packed for shipment. The platform arrives on
dollies so that you are able to move it directly into position in the mill. Refer to
Figure 3-1. Depending on the location of the mill, some Smart Platforms will arrive
with the dollies bolted to a skid. For those shipments, unpacking instructions are
posted inside the crate.
Figure 3-1 Smart Platform on Shipping Dollies

Various components and cables are removed and packed separately for shipment.
The Smart Platform comes with a bill of lading.
Use the checklist below during the unpacking process.
Checklist
❏ Inspect the platform and components for dents, scratches, and damaged parts.
❏ Verify that the delivered components match the bill of lading.
❏ If there is minor damage, make a note of the damage on the bill of lading.
Photograph the damage, when possible.
❏ If there is major damage, immediately notify the ABB shipping department in
Columbus, Ohio or Dundalk, Ireland.
24 Hardware Installation 101764-003


Handling Instructions
The Smart Platform arrives on dollies so that it can be maneuvered into place at the
mill. Use caution when rolling the platform on an uneven floor to keep from getting
the wheels stuck in a hole. If you need to lift the platform, see Figure 3-2 on page 26
and make certain that you observe the following guidelines:
• Attach any rigging used to the two lifting eyes on top of the platform.
• Lifting forces must be spread over 75% of the platform.
• Do not lift from one point.
• Use a crane or hoist to move the platform (a dual pulley house crane is preferred
to prevent weight distribution problems).
• Make certain that the platform is not subjected to bending and twisting forces.
• Do not bump or drop the platform.
• Secure the platform from movement while it is being stored.


Best
Dual Pulley House Crane
SMART PLATFORM
Good
Spreader Bar
SMART PLATFORM
Possible
If lift angle is 30˚ or more
Minimum 30˚
SMART PLATFORM
Unacceptable
SMART PLATFORM
Figure 3-2 Rigging Recommendations


Dimensions and Weight

The Smart Platform 1200 is supplied in standard lengths between the pedestal center
lines as indicated in Table 3-1. Weights include sensors and dollies.
Table 3-1 Dimensions and Weight
Dash Standard Length
Number for Hole Centers Maximum Trim Weight
(mm in) (mm in) (kg lb.)
004 4000 157.5 2235 97.9 1659 3661
005 5000 196.9 3235 127.4 1925 4248
006 6000 236.2 4235 166.7 2191 4710
007 7000 275.6 5235 206.1 2457 5243
008 8000 315.0 6235 245.5 2723 6011
009 9000 354.3 7235 284.8 2989 6597
010 10000 393.7 8235 324.2 3255 7184
011 11000 433.1 9235 363.6 3521 7773
012 12000 472.4 10235 403.0 4787 8358
Space Requirements
Installation requirements are dependent upon the facilities and space available at
the site location. Refer to the general installation plans made prior to installation
of the Smart Platform.
The customer–supplied platform supports must be flat and unobstructed. Allow
sufficient access space around the support for cables to be connected and
disconnected.
It is advisable to drill necessary cable holes through the concrete floor before the
pedestals are mounted. A single hole of approximately 3 in. (75 mm) in diameter
and located near the idler end is sufficient. A similar hole can be used for the liquid
cooling unit. See Figure 3-3 on page 34.


Safety
The Smart Platform 1200 has been designed to comply with ABB and worldwide
standards including the following:
• ABB PA Electrical Safety Directive, 3BDU000002
• ABB PA Machinery Requirements and Policy, 3BUS000159
• ABB PA Field Installation Considerations for Design of Electronics,
3BSE000161
• ABB PA EMC Requirements and Policy, 3BSE000200
The following personnel and machine safety rules should be followed when
installing and operating the Smart Platform 1200.
Personnel
Symbols appearing on the equipment warn personnel

of potential hazards. Symbols for dangerous voltage
warning, radiation warning, crushing hazard warning,
hand entrapment hazard warning, moving machinery
warning, and a warning that equipment may
automatically start up are shown on the left. Refer to
the explanations in the Caution and Warning Symbols
section at the beginning of this manual.
All people working on the SP1200 system must

know the location of the main power supply
switch to the system and how to operate it.
Service on the SP1200 system is to be performed

only by qualified, trained personnel. Hazardous
voltages exist inside the AccuRay Smart
Processing Center (ASPC) and in the SP beam.
Work with care when supply voltage is applied in

the SP system. The voltage in the ASPC and the
SP beam can cause injury and can even be fatal.


Machine
Avoid discharges of static electricity by grounding both

yourself and tools before handling circuit boards and
other parts of the equipment.
Use the grounded wristband installed in the cubicle

when handling parts of the system.
Always store circuit boards in approved anti-static bags

when not installed in the system rack.
Always switch off the voltage before extracting or

inserting a board.
Switch off voltage to the system and withdraw all boards

at least 2 cm before electrical welding is performed near
the SP1200.


Installation Requirements
Environmental Data
Table 3-2 lists some of the standard parts of the Smart Platform 1200 system and
the maximum ambient temperatures in which they were designed to be used.
Table 3-2 Environmental Data for the SP1200
Part ˚F ˚C Rel. Hum.
SP1200 175 80 95% non-condensing
Remote ASPC Junction Box 120 50 90% non-condensing
(Optional)
SPDC 120 60 95% non-condensing
Purge Blower 120 60 80% non-condensing
Liquid Cooling Unit (LCU) 110 43 95% non-condensing
If the temperature around the idle end column is above 50°C, then the ASPC severe
environment option which moves the ASPC into a Remote Junction Box like
enclosure is required.
Electrical Supply and Grounding Requirements
Supply
The signal-processing electronics in the Smart Platform 1200 is chassis-grounded
and all suppression of external signal noise uses the chassis as a reference ground.
If this requirement is not satisfied, the SP1200 system may be sensitive to high
frequency interference from unsuppressed relays, contactors, and the discharge of
static electricity.
The main power supply to the SP1200 must be from the same power supply as the
host system. If there must be a deviation, then the two supplies must be bonded to
the same ground (single point earth reference).
Grounding
• The electrical connections of the reference ground are to be effective and
permanent.
• The cable shields are to be connected to the chassis with a short lead of less
than 10 cm (0.5 inch).
• The introduction of an extra grounding system such as an instrument ground is
absolutely forbidden. The system is to be grounded with a copper lead to the
distribution box (single point earth reference).


Smart Platform Distribution Center (SPDC)

The main power supply to the SP1200 must be from the same power supply as the
host system. If there must be a deviation, then the two supplies must be bonded to
the same ground (single point earth reference).
A neutral to ground bond must exist on the secondary side of the Smart Platform
Distribution Center (SPDC). This bond must be only in the SPDC.
The SPDC is 10KVA and can handle the largest SP1200 system including the purge
blower and Liquid Cooling Unit. Even if your installation does not consume that
much power, the input wiring, fusing, and disconnect should still be sized for the
full 10 KVA.
Allowable input voltages to the transformer are:
• Rated Input Voltage: 240, 230, 220, 208, or 200 volts ± 10%
• Rated Frequency: 50 or 60 Hertz (Hz) ± 1%
• Rated Current: 41.7 amps @ 240 VAC
The secondary is always wired as 120/240 volts alternating current (VAC).
Cabling
The National Fire Protection Association (NFPA), Publication No. 70 “The
National Electric Code (NEC)”, Article 725 states that Class 1, Class 2, and Class
3 Remote-control, signaling, and power-limited circuits acknowledges alternative
requirements for circuits characterized by usage and electrical power limitation. It
specifies less stringent requirements than those for general wiring elsewhere in the
code.
The SP1200 utilizes ± 12 volts with adequate isolation to be safe without further
protective measures, even in wet environments. However, due to the amperage
available, it does not qualify as power-limited. Any of the circuits with direct ties
to the ± 12 volt power supplies qualify as “Class 1 Remote-Control and Signaling
Circuits” as defined by NEC Article 725-11b and as such, require insulation suitable
for 600 volts.
The serial communications circuits satisfy the “inherently limited” clause in Article
725-31 and may be wired using the Class 2 (or Class 3) rules. The cables provided
by ABB for these circuits are dual rated CL3/PLTC with 300 volt insulation.
NEC Article 725-52a(2) prohibits conductors of Class 2 or Class 3 circuits from
being “placed in any cable, cable tray, compartment, enclosure, outlet box, raceway,
or similar fitting with conductors of electric light, power, Class 1, and non power-
limited fire protective signaling circuits”, except where conductors of the different
circuits are separated by a barrier.


Cable requirements are as follows:

Cable Use Cable Type Max. Run
Comm Link from ASPC to Host 20mA 1000 ft.
(customer supplied black box
required)
Comm Link from ASPC to SWS RS232 / 20 mA 15 ft./1000 ft.
Operator Panel to ASPC connectorized 75 ft.
(standard
length)
Equipment Location
The location of the ASPC, the SPDC, the operator panel, and the blower will be
site specific. Refer to the System Specifications prepared prior to your installation
for details on where each component will be installed.
ASPC Location
The ASPC is designed to be securely mounted to the wall in the paper mill facility.
Refer to Drawing DC-D-130181-001 for details on the weight and hole pattern
required for mounting the ASPC. For information on termination, refer to the
appropriate wire list.
A connection terminal block for the supply voltages is located behind the cover over
the main circuit breakers. The phase conductors of the main 120/240 VAC terminate
directly to the main breaker; neutral and ground to the adjacent terminals.
The European service power and the system 120/240

must be bonded to the same ground.


Smart Platform Power Distribution Center (SPDC)

The Smart Platform Power Distribution Center (SPDC) is designed to be securely
mounted to the wall in the paper mill facility.
Operator Control Panel Location
Refer to Drawing DC-D-121599-001 for information on the location and mounting
requirements for the operator panel.
Blower Location
Refer to your blower specific drawings for information on its location and mounting
requirements.


Liquid Cooling Unit Setup

Setup procedures for the liquid cooling unit are available in the
AccuRay 1190 Liquid Cooling Unit Reference Manual, 101333-003.
WEB
Cable/Plumbing
Hole
PLATFORM
Idler End Drive End

Pedestal Pedestal
COOLING
UNIT Cable\Plumbing
Hole
Figure 3-3 Liquid Cooling Unit Setup


Pedestal Installation and Alignment

The ultimate objective of the pedestal installation and alignment procedure is to
ensure a precise dimensional relationship between the source heads, the detector
heads, and the process. This objective can be achieved by following the guidelines
and procedures in this section.
Installation Guidelines
Observe the following guidelines when installing the Smart Platform.
• The pedestals must be stable in the machine direction and cross–machine
direction.
• The pedestals must be level in the machine and cross–machine direction.
• The pedestal center lines must be perpendicular to the machine direction and
to the sole plate.
• The top surfaces of the pedestals must be in the same horizontal plane.
• The top surfaces of the pedestals must be at the prescribed distance from the
sheet pass line through the center of the Smart Platform.
• The height of the platform and the angle of the sensor heads may have to be
adjusted to compensate for the process angle.


Alignment of the Customer Pedestals

Refer to Figure 3-4 while aligning the pedestals.
Weight
Check specified
off sheet Piano Wire or
location Machinists String
Any Paper Roll
Check
back
distance
Paper Web
Check distance
between
mounting bolts
Machine
Direction
Check
front
distance
Set pedestals
90° against
piano wire
Weight
Figure 3-4 Alignment of the Mounting Pedestals


1. Scribe a center line on each pedestal exactly halfway between the mounting
bolt pattern and perpendicular to the machine direction.
2. Stretch a length of piano wire, (0.012 in./0.3 mm) in diameter, (or thin, strong,
machinist’s string) between the two mounting pedestals.
3. Attach a weight to each end of the wire (approximately 10 lb./5 kg). The wire
should pass over the scribe lines on the pedestal’s top surface.
4. Adjust both mounting pedestals by gently tapping their sides with a hammer
until the piano wire passes directly over the scribe lines for both pedestals.
5. Visually determine that the wire and the scribe lines coincide within 0.04 in./
1 mm along a 8 in./200 mm length on each pedestal.
6. Make certain the distance between the pedestals and off sheet location (center
line to center line) corresponds to the dimensions on the site specific
engineering drawings.
7. Determine that the top surfaces of the two pedestals are at the same elevation.
If the pedestals must be leveled, then recheck the alignment of the scribe lines
after completing the leveling.
8. Determine that the piano wire is parallel to the adjacent process rolls within
0.08 in./2 mm by measuring the back and front distances of the roll to the piano
wire with vertical plumb lines.
The mounting pedestals are now aligned.


Attaching the Platform to the Pedestals

This section describes the attachment of the Smart Platform to the pedestals.
1. Transport the Smart Platform on its shipping dollies or skids to the installation
site.
2. Remove the end column doors to avoid damaging them during placement.
3. Coat the entire top surface of both pedestals with a corrosion preventive
compound.
4. Install shims. Refer to Figure 3-5 and Figure 3-6 on page 39.
Install the 0.5 in. (13 mm) plate at the idler end. Install the 0.375 in.
(10 mm) plate and the 0.25 in. (3 mm) Teflon® pad at the drive end.
Drive Side Slot to allow for aligning

platform parallel to process
rolls, and calender.
Base 25 mm (1.0 in.) thick
If tapped 1.25 in. holes are used in the

pedestals instead of through holes for
mounting the platform, drill and tap
3/8 x 16 or M10 x 1.5 through to tapped
hole for set screw to lock mounting bolt.
Steel mounting plate
3 mm (0.50 in.) thick.
Seating for screws
Figure 3-5 Platform to Pedestal Installation – Drive Side


Tighten this screw to 1/2 compression of lock washer. Use

1.25 in. or M30 bolt with lock washer and large flat washer (customer
supplied). Use a thread–locking compound to avoid vibration
loosening. Screw cannot be tightened hard; it is an expansion
mount.
Jack/leveling screws
Thermal
Expansion Slot
Idler Side
The top of customer pedestals to

Base 25 mm (1.0 in.) thick pass line is normally 953 mm
(37.50 in.). For standard end
column includes manufactured
plates and 6 mm (0.25 in.) extended
set screw, (both end columns).
Steel mounting plate 10

mm (0.375 in.), seating
for set screws
Teflon plate 3 mm (0.125

in.) thick Tapped holes or
nut on backside
If tapped 1.25” holes are used

in the pedestals instead of
through holes for mounting the
platform, drill and tap 0.375 x
16 or M10 x 1.5 through to
tapped hole for set screw to
lock mounting bolt.
Figure 3-6 Platform to Pedestal Installation – Idler Side

5. Make certain that the mounting surfaces on the bottom of the platform are clean
and smooth.
6. Coat the entire surface on the bottom of the platform with a corrosion preventive
compound.
7. Thread two parallel lengths of wire over the rolls onto which the process is to
be guided. Refer to Figure 3-7 on page 40.
These wires should be placed in the positions that are representative of the
outside edges of the process sheet.
8. Suspend a weight of approximately 5 lb. (3 kg) from each end of the wire.


Stretched wire
representing sheet
edge
Weight
(Typical)
Customers
Roll
Figure 3-7 Preliminary Alignment Setup

9. Check the dimension from the customer pedestals to the process being
simulated by the wires. Make sure that this dimension corresponds to the
dimension on the Smart Platform specification drawings. These drawings are
customized for each installation site.
10. Temporarily remove the two parallel lengths of wire to allow placement of the
Smart Platform.


11. Install eight jackscrews in the platform mounting bases.

Refer to Figure 3-8.
The four front (inner most) jackscrews should protrude 0.125 to 0.25 in.
(3 to 6 mm) below the mounting surface, and the remaining jackscrews should
be flush with the mounting surface.
Inner
Jackscrews
Hold
Down Bolt
Outer
Jackscrews
Drive End Idler End
Figure 3-8 Jackscrew Orientation

12. Connect a heavy duty cable or chain through the two large lifting lugs located
on the top beam of the Smart Platform.


13. Using the lifting device, secure it to the cable or chains connected to the lifting
lugs.
14. Carefully lift the Smart Platform from the transporting skid or dolly and position
it on the customer pedestals so that the platform and the support structure
mounting holes are aligned.
The mounting holes center–to–center dimension should be within
3 mm (0.125 in.) of the dimension noted on the dimensional outline drawing.
The dimensional drawing is site specific.
15. Install four customer–provided hold–down mounting bolts, leaving them loose
enough for Smart Platform alignment later.
The platform is now in position.
16. Rethread the two parallel lengths of wire over the rolls onto which the process
is guided. Refer to Figure 3-7 on page 40.
17. Verify that the wire locations represent the outside edges of the process sheet.
18. Separate the head assembly.
19. Manually move the lower carriage assembly close to the wire at one end of the
platform.
20. Adjust the jackscrews in the base of the applicable column to position the Beta
source detector window 0.25 in. (6 mm) below the wire. See Figure 3-5 on
page 38 and Figure 3-6 on page 39.
21. Move the carriage assembly to the other end of the Smart Platform.
22. Adjust the front jackscrews to position the wire in the center of the source
detector air gap.
23. At the drive end of the platform, compress the lock washer approximately half–
way.
24. At the idler end of the platform, tighten the screws securely.
25. Verify that there is approximately equal travel remaining in each direction in
the slotted holes in the drive end pedestal.
This completes the preliminary installation of the Smart Platform.


Platform Alignment
To accomplish alignment of the Smart Platform, proceed as follows:
1. Place a machinist’s level on the leveling blocks located on the inner side of each
end column. See Figure 3-9.
Do not make any adjustments to the alignment block.

The adjustment block is factory adjusted. Any
adjustment will render the block unusable.
Alignment
Block
Machinist’s
Level
Figure 3-9 Verifying Platform Alignment

2. Loosen the hold–down mounting bolts.


3. Adjust the inner jackscrews on the end column to zero the level at one column,
and repeat for the column at the other end of the platform.
Maintain the same orientation of the machinist’s level at both ends of the
platform.
4. Check the position of the wire in the air gap to assure that the pass line angle
is unchanged. Should the angle appear to have changed, repeat Step 3.
5. Adjust the outside jackscrews down against the mounting support.
The adjusted jackscrews should be snug, but they should not lift the platform
off the front (inner most) jackscrews which are already precisely set.
6. Place the machinist level on the leveling blocks to monitor the final settings and
to make certain no changes in leveling occur.
7. When all four jackscrews at one of the columns are adjusted satisfactorily,
tighten the hold–down mounting bolts to secure the Smart Platform to the
support structure.
Do not over stress the mounting bolts.
8. Repeat Steps 1. through 7. for the other column.

9. Remove the wires.
This completes the Smart Platform alignment.


Carriage Alignment
The mechanical alignment (relative positioning) of the sensor’s upper and lower
heads is critical in maintaining proper measurement characteristics. Both the static
(off–sheet) and the dynamic (scanning) alignments must be correct. Static and
dynamic alignment conditions (see Figure 3-10) which should be considered for
the sensor heads include the following alignments and adjustments:
• Pass Angle Adjustment (see “Pass Angle Adjustment” on page 46.)
• Process Direction (Lateral Alignment)
• Air Gap Dimension (Vertical Spacing)
• Scan Direction (Horizontal Alignment)
These alignment and adjustment procedures are in the following sections.
Upper
Head
Process
Direction
Scan
Air Gap Direction
Process
Lower Head
Figure 3-10 Head Alignment Conditions


Pass Angle Adjustment

This procedure describes how to make adjustments to the pass angle. To insure
proper alignment of the sensor carriage assembly, you will perform a process
direction alignment and an air gap alignment at the same time. Refer to Figure 3-11.
Adapter Plate
Extension Upper Radial Plate
Mounting Bolts
Upper Adapter Plate
Adapter Plate Mounting

Pass Angle Bolts with Eccentrics
Adjustment Tool
Adapter Plate
Mounting Bolts with
Large Parallel Face
Washers
Lower Adapter Plate

Adapter Plate Mounting Bolts
Lower Radial Plate
Figure 3-11 Pass Angle Adjustment
Note: Whenever a pass angle change is made, no matter how slight, be

sure to follow the procedure below.
1. Move the sensor head package to the off–sheet position.

2. Place the platform in local by pressing the LOCAL push button on the control
panel.
3. Turn off the power to the platform.
4. Activate the head separation switch located at either end of the Smart Platform
in the service outlet box.
Deactivating the clutch trips a switch which also causes the platform to enter
the local mode.
5. Manually separate the heads.
6. Remove the lower carriage electrical enclosures on both sides of the carriage.
See Figure 3-11.


7. Using a 13 mm socket or wrench, loosen the four locking M8 bolts (lower

adapter plate mounting bolts) in the curved slots on each side of the bottom
carriage.
8. Thread two parallel lengths of wire over the rolls onto which the process is
being guided. See Figure 3-12.
These wires should be placed in the positions that are representative of the
outside edges of the process sheet.
9. Suspend a weight of approximately 5 lb. (3 kg) from each end of the wire.
Stretched wire
representing sheet
edge
Weight
Customers Roll
Figure 3-12 Simulating the Process Pass Line

10. Rotate the lower head to the desired pass angle.
11. Tighten the four locking M8 bolts (lower adapter plate mounting bolts) on each
side of the bottom carriage. See Figure 3-11 on page 46.
Note: Prior to removing the electrical covers on the upper carriage

assembly, wipe them of any accumulated dirt or moisture to avoid
damaging exposed components.
12. Remove the top cover and electrical enclosures from each side of the upper
head. See Figure 3-11.
Note: Lift the carriage seal sled manually to allow free removal or insertion
of the electrical enclosure.
13. Loosen upper adapter plate mounting bolts with parallel face washers and
remove the mounting bolts with eccentrics. See Figure 3-11.
14. Loosen the adapter plate extension mounting bolts. See Figure 3-11.


15. Adjust the four vertical adjustment screws so that the weight of the upper
carriage rests on the bolts of the upper adapter plate.
This is done so that when you adjust the air gap between the upper and lower
sensor heads you have enough slack to move the upper head vertically.
16. Rotate the upper head package to approximate pass angle and move the upper
head package directly over the lower head package.
17. Rotate the upper head package to match the lower head package angle closely
by visual inspection.
18. Tighten the upper adapter plate extension mounting bolts. See Figure 3-11 on
page 46.
Note: When aligning the head packages, all reference points will be located
on the Basis Weight sensor plate. If a Basis Weight sensor is not
present, use the Ash sensor for the alignment reference. If neither
Basis Weight or Ash sensors are present, use the Basis Weight/Ash
sensor blank base plate.
19. Align the upper and lower base plates of the Basis Weight sensor using the
procedure for Process Direction Alignment below.
20. Continue with the “Air Gap Alignment” on page 52..
21. Finally, verify the “Scan Direction Alignment” on page 54..


Process Direction Alignment
Note: When aligning the head packages, reference points will be located
on the Basis Weight sensor plate. If a Basis Weight sensor is not
present, use the Ash sensor for the alignment reference. If neither
the Basis Weight or Ash sensors are present, use the Basis Weight/
Ash sensors blank base plate. If a Smart Caliper GT is present, one
reference point will be located on the caliper sensor.
1. Use a machinist straight edge (or the back side of the air gap tool (Part Number
128624-001)) to make certain that the upper and lower heads are parallel. They
should be flush within ± 0.005 in. (0.127 mm). See Figure 3-13.
Upper
Head
Machinist’s
Straight Edge
Use Feeler
Gauge Here
Lower
Head
Figure 3-13 Process Direction Alignment Points

2. Place the straight edge against the machined surface on the upper and lower
base plates of the Basis Weight sensor. If the plates are perpendicular to the
straight edge, they are parallel to each other.
3. Align the upper head to the lower head using the horizontal adjustment bolts
on the adapter plate extension. See Figure 3-14 on page 50.
4. Turn the horizontal adjustment bolts clockwise to move the upper head towards
you; counterclockwise to move the upper head away from you.


Do not force the horizontal adjustment bolts if binding is

felt. Instead, loosen both bolts before resuming
alignment.
The horizontal adjustment bolts have to be adjusted with respect to each other
to avoid binding the upper head carriage. For example, every half–turn of one
horizontal adjustment bolt necessitates a half–turn to the other.
Carriage Extension Plate
Vertical Adjustment Bolt
Horizontal
Alignment Rod
Vertical Adjustment Bolt

Upper Adapter Plate
Extension Mounting Bolts
Upper Adapter Plate

Extension
Mounting Bolts
Horizontal
Adjustment Bolt
Eccentric
Upper Adapter Plate

Mounting Bolts
Adapter Plate
Figure 3-14 Upper Head Carriage


WITH SMART CALIPER GT
Alignment Points
At each alignment point, set gap to

7.5 ± 0.5 mm (0.295 ± 0.02 in.) cold.
WITHOUT SMART CALIPER GT
Alignment Points
Figure 3-15 Air Gap Alignment Points


Air Gap Alignment

Refer to Figure 3-14 on page 50 and Figure 3-15 on page 51 while performing the
air gap alignment procedure.
1. Use the vertical adjustment bolt to achieve a 7.5 ± 0.5 mm (0.295 ± 0.02 in.)
cold air gap between the base plates along the on-sheet end of the sensors and
at the points designated in Figure 3-15. For every half turn of a vertical
adjustment bolt, do a half turn to its opposite adjustment bolt. Across the sensor
window, check the distance using the air gap tool provided with the platform.
If bolts seem to bind at any time, adjust the opposite side air gap before
proceeding.
Note: You need to protect the carriage assembly from damage from
mechanical forces by not positioning the vertical adjustment bolts
such that the weight of the carriage is supported on three bolts
instead of four as this may twist the carriage. Also, never rest the
upper head package weight on the lower head package by leaving
the air gap tool between the sensors.
2. Adjust the off–sheet side air gap to 7.5 ± 0.5 mm (0.295 ± 0.02 in.) cold.
3. Continue to adjust the vertical adjustment bolts until the specified air gap is
achieved.
4. After acceptable air gap is set, make certain the sensor is still aligned in the
process direction. Refer to the “Process Direction Alignment” on page 49.
5. Tighten the bolts which have large parallel face washers onto the upper adapter
plate.
6. Replace bolts with eccentrics.
7. Rotate the eccentrics on the adapter plate extension so that they bear the weight
of the upper head assembly.
8. Tighten the bolts that hold the eccentrics in place.
9. To insure that the top electrical covers will fit, the alignment mechanism should
be centered over the adapter plates.
a. Loosen adapter plate extension mounting bolts.
b. Use the horizontal alignment bolt to center the alignment mechanism over
the adapter plates.
c. Center the horizontal alignment rod in its slot.
d. Tighten the extension mounting bolts.
10. Tighten the bolts on the adapter plate, both sides.
11. Replace the electrical covers.
This completes the Air Gap Alignment Procedure.


Verify Air Gap

Sensor calibration is performed at the factory prior to equipment shipment to meet
the specific requirements of the sensor’s on line use. The optimum air gap
dimension is specified in the Calibration Report.
To perform measurement of the air gap dimension, proceed as follows:
1. Insert the Gap Measurement Tool, part number 128624-001 and measure the
gap size at the specified alignment points of the Basis Weight sensor and Smart
Caliper GT (if present). See Figure 3-15 on page 51 and Figure 3-16.
Air gap specifications are shown in Figure 3-15.
Upper
Head
Gap Tool
(6 in. long)
(Enlarged
for Clarity)
Lower
Head
Figure 3-16 Air Gap Measurement Tool

2. Compare the measurements to the Calibration Report.
3. If the air gap dimension is not within tolerance, perform “Air Gap Alignment”
on page 52.
Note: The air gap and process direction alignment changes are
interdependent. It may be necessary to repeat the “Process
Direction Alignment” on page 49.
4. Realign the sensor heads.


Scan Direction Alignment

The scan direction alignment is checked both close to the drive end column and
close to the idler end column on the scanner.
Alignment at the drive end is set by drive pulley phase adjustment. Alignment at
the idler end is controlled by belt tension.
The scan direction alignment procedure is as follows:
1. Jog the sensor heads near the drive end column.
2. Apply a straight edge and feeler gauge to the machined surface on the upper
and lower sensor heads. Refer to Figure 3-17.
Upper
Head
Use Feeler
Gauge Here
Machinist’s
Straight Edge
Lower
Head
Figure 3-17 Scan Direction Optimum Alignment Point


The machined ears should be flush within + 0.005 in. If they are not:
a. Loosen the upper drive belt pulley locking screws.
b. Adjust set screws for phasing of the pulley until the heads are parallel.
c. Tighten the screws when finished.
3. Jog the heads near the idler end column.
4. Apply a straight edge and feeler gauge to the machined surface on the upper
and lower heads.
5. If they are not aligned in the scan direction within ± 0.010 in., adjust belt tension
in the upper or lower belts by means of the idler bracket adjustment screws.
See Figure 3-18.
Drive Idler
End End
Adjust phase Adjust belt tension

of drive pulley of idler pulley
to make heads to make heads
parallel here parallel here
Drive Pulley Lock – Idler End Belt

Loosen to rotate pulley Tension Adjustments
for Phase Adjustment.
Figure 3-18 Scan Direction Adjustment

6. Use the belt tensiometer (Part Number 122146-004) to check the belt tension.
The range is specified on the tensiometer.


Note: The belt may be installed in such a way that the upper and lower
heads are off by more than one tooth on the belts. This can be
corrected by inserting a short strip of thin sheet metal or hard plastic
between the belt and drive pulley and allows for manual alignment
to the next tooth. Refer to Figure 3-19.
Rotate by hand to Thin Metal or

get strip between Plastic Strip
tooth of pulley
and belt
Drive Pulley Belt
Figure 3-19 Manual Alignment Setup


4
Utility Service Installation
Section............................................................................................... Page
Air Purge ....................................................................................................... 58
Air and Water Supply .................................................................................... 59
Electrical Hook–Up ....................................................................................... 61
SP1200 Power Up Procedure ........................................................................ 63
Starting Up the Software ............................................................................... 67
101764-003 Utility Service Installation 57


Air Purge
The Smart Platform 1200 is air purged to assure reliable operation in a paper mill
environment. The purge air duct is attached to the idler end column either directly
or with a flexible air hose. If a flexible air hose is used, the flexible portion of the
hose should be less that 10 ft. (3 m) to avoid a drop in pressure. Refer to Figure 4-1.
NOTE: Designed to accommodate

6” I.D. Duct
Typical
Installation
Idler End Column
Figure 4-1 Purge Air Duct Attachment
Note: Do not allow the weight of a heavy metal air duct to rest on the plastic
top cap. Off load the duct by means of bracing to the machine
foundation or use a flex ducting.
The source of air for air purge can be supplied by either the DC motor cooling air
or the ABB purge blower. Clean DC motor cooling air has the advantage of no
special air filter maintenance and is generally preferred when available. If the DC
motor cooling air is used, an adjustable damper is needed to reduce the air flow and
avoid excessive system pressure loss (especially when the doors are opened).
For installation of the ABB purge blower, refer to the instructions which are supplied
on the illustration drawings.
Normal applications should operate with the platform fully sealed. For high
temperature applications, a continuous air flow must be supplied through the scanner
beams to the drive end.
58 Utility Service Installation 101764-003


Air and Water Supply

Sensors require clean, oil free, dry compressed air for operation. The pressure at
the platform air inlet ports must be at least 4.4 bar (65 psi) and a maximum of
5.4 bar (80 psi). The air flow depends upon the sensor configuration and the
adjustment of the manifold valves (the range is typically 0.37 m3/min (13 scfm) to
0.6 m3/min (21 scfm). Refer to the appropriate sensor manuals for further
information.
The SP1200 clutch has a separate air regulator. Approximately 30 to 40 psi is
required to operate the clutch.
The liquid cooling unit provides a closed loop water circulation system to the
electronics on the platform and IR sensors. The liquid cooling unit requires
secondary heat exchange, a water supply of less than 80°F (27°C), and a flow of
typically less than 5 liters/min (1.5 gpm). Figure 4-2 on page 60 illustrates a typical
hook–up.
During installation make sure that the liquid cooling unit is filled according to
instructions and that the air supply is on before proceeding with the electrical power
up.


Idler
End Liquid Cooling Unit
Water Filter
Supply xxxx-x
Shut–off
valve
Drain
Type 3/8” (10 mm) tubing

2 Water lines (1 to frame, 1 returns)
Air Filter
Air Regulators
1” Shut–off
Top Sensor Air Supply
Valve
Type 1” (25 mm)
tubing
Bottom Sensor Air
Air Supply
Type 1/2” (13 mm) tubing
Air Filter
Clutch Air
Top Caliper Air Air Supply
Bottom Caliper Air
Figure 4-2 Air and Water Hookup


Electrical Hook–Up
Cabling to a Smart Platform is minimal. All that is normally required for hook-up
are the AC power, serial communication loops to the host system and Service
Workstation, sheet break detector, Liquid Cooling Unit (LCU) flow switch (es), and
reel turn-up detector. Other auxiliary equipment (for example, microwave or
smoothness processors), depending upon the configuration, may also require cables
to the AccuRay Smart Processing Center (ASPC).
For details of the TCP-IP Ethernet connection to the 086444-001 MPRC, see ABB
Functional Drawing 086424-201. This drawing outlines the details of the required
132573-001 “Y” cable which plugs into J6 “HOST” connector on the ASPC
backplane. It also shows the redundant Ethernet port which exits the electronics
enclosure through an aluminum shield grounding block attached to the front door
of the ASPC. This redundant Ethernet port is normally not present. A Fiberoptic
Transceiver (ABB 102204-001) is required to meet CE Mark Radio Frequency
emissions and susceptibility requirements. Using twisted pair or coaxial Ethernet
transceivers is not certified to meet CE Mark. The suggested fiberoptic cable is
ABB 102205-001 with 102206-001 “ST” connectors. These “ST” connectors
require special tooling such as the ABB 102206-100 tool kit.
The platform is connected to customer power via the Smart Platform Power
Distribution Center (SPDC). The SPDC also provides the power for the purge
blower, Liquid Cooling Unit (LCU), and various auxiliary equipment. The SPDC
is an integral part of the SP electrical design and is required to meet electromagnetic
compliance (EMC) specifications and standards. See Figure 4-3.


Power
Purge Blower Distribution
Center
SP/1200
AC Power
Idler End Column
Back Plane Connectors
AC
Liquid
Cooling
Unit
Flow
Switch Cable
AC Power/Ground Cable
Customer A
Power
208
210
220
230
240 VAC
Reel
Turn up
(Process Signals)
Sheet
Break
Workstation
Serial
To Computer
Room
System Serial to 1190
Figure 4-3 Standard Cable Configuration

The main supply to the SP is to be from the same supply as the host system. If there
must be a deviation, then the two supplies must be banded to the same ground (single
point earth reference). The introduction of an extra grounding system such as an
instrument ground is absolutely forbidden.
A neutral to ground bond must exist on the secondary side of the SPDC. This bond
must be in the SPDC and only in the SPDC.
The SPDC is 10 KVA to handle the largest SP system. You particular installation
will probably not actually consume that much power. The input wiring, fusing, and
disconnect should, however, still be sized for the full 10 KVA.
Allowable input voltages to the SPDC are:
• Rated Input Voltage: 240, 230, 220, 208, or 200 volts ± 10%
• Rated Frequency: 50 or 60 Hz ± 1%
The secondary is always wired as 120/240.


SP1200 Power Up Procedure

The following power up sequence is required to ensure no wiring errors or
malfunctioning equipment cause a failure that could jeopardize a successful
installation.
1. Verify power is tagged off and locked out at the Motor Control Center (MCC).
2. Verify all SPDC SP1200 circuit breakers are turned off (see Figure 4-4).
Head Split Switch
Figure 4-4 Circuit Breakers

3. Remove all debris from the installation work and vacuum the enclosure. Verify
no tools or assembly material were left in the equipment.
The neutral to ground bond is extremely important. If it

is not correct, the electronic filter in the ASPC may be
destroyed when power is applied.


4. Verify there is a neutral to ground bond at the SPDC, and ONLY at the
transformer. Ensure that the primary and secondary are correctly terminated.
5. Verify all of the ASPC cabling is correctly terminated.
6. Unplug the Host and Service Workstation from the ASPC. Unplug all other
external I/O cables (Sheet-Break, Reel Turn-up, chiller flow switches, etc.).
7. Remove the lock-out on the MCC and turn on the power to the SPDC. Measure
the primary voltages (phase to phase, phases to neutral, and phases to ground)
to verify proper power, grounding, and tap selection.
8. Turn on the Primary main circuit breaker and measure the secondary voltages
(phase to phase, phases to neutral, and phases to ground). The output must be
240 VAC ± 10% phase to phase; and 120 VAC ± 10% each phase to neutral and
each phase to ground.
9. Turn on the secondary circuit breakers and securely fasten all transformer
covers.
10. Measure the input voltages on the line side of the SP1200 main breaker. The
SP1200 input must be 240 VAC +10%, -14% phase to phase; and 120 VAC
+10%, -14% each phase to neutral and each phase to ground.
11. Switch on the SP1200 main breaker and the Service breaker. Check for 120
VAC at the service outlet.
12. Switch on the DC breaker and check the ± 12 Volts on the I/O connectors on
the backplane. Refer to the appropriate SP1200 positioning functional drawing.
Verify that the LEDs are operating correctly. See Table 4-1 on page 65 and
Table 4-2 on page 65 .
13. Switch off the main breaker.
14. Securely fasten the power entrance cover.
15. Plug in the Service Workstation, power, comm, and Air Pressure Transducer
cables.
16. Switch on all the appropriate branch circuit breakers before switching on the
main breaker. This is to allow the heater power-on sequencing in the software
to minimize the heater turn on surge currents. The system is now ready for
software loading and setup.
The following tables explain what the various LEDs are on the ECPSR and MPRC.


Table 4-1 ECPSR LEDs

LEDs Description
DC IN This LED refers to the 24 VDC power supply for the
ASPC.
When this LED is lit, the power supply is on but may not
be within acceptable tolerance.
DISABLE This LED refers to a remote disable input to the ECPSR.
When the LED is lit, the -12 VDC are out of spec and the
ECPSR is disabled.
+15 V These LEDs refer to the presence of their respective

-15 V voltages within the ASPC.
+5 V When these LEDs are lit, the respective voltages are
within acceptable tolerances.
Table 4-2 086349-002 MPRC LEDs

LEDs Description
ERROR (red) This LED indicates status of local diagnostics; it is under
software control on a reset.
If the LED stays on after reset, replace the MPRC.
If the LED is flashing, check the service console.
If the LED is off and the RUN light is flashing, conditions
are normal.
If the LEDs are not lit, check to make certain there is power
to the board.
RUN (green) This LED is driven by the data strobe and indicates the level
of 68332 external bus activity.
The intensity of the LED varies from dim to bright
depending upon bus activity.
RX TERMINAL When the LED is lit or flashing, there is a physical
connection to the terminal.
When the LED is not lit, the physical connection to the
terminal is broken.
RX HOST When the LED is lit or flashing, there is a physical
connection to the host.
When the LED is not lit, the physical connection to the host
is broken.


Table 4-3 MPRC 086444-001 LED Interpretation

LEDs Description
are normal.
to the board.
RUN (green) This LED is driven by “Transfer in Progress” and indicates
the level of 68040 external bus activity.
NET TX_B (green) When lit, the Ethernet port on J2 (Port B) is transmitting
data.
NET TX_A (green) When lit, the Ethernet port on the ASPC Host Connector
(Port A) is transmitting data.
RTS 0 (green) HDLC Port 0 is transmitting to the sensor microcontrollers.
RTS 1 (green) When lit, HDLC Port 1 is transmitting to the sensor
microcontrollers.
RTS 2 (green) When lit, HDLC Port 2 is transmitting (unused in Smart
Platform).
Platform).
(green) connection to the terminal.
terminal is broken.
RX HOST (green) When the LED is lit or flashing, there is a physical
is broken.


Starting Up the Software

The Service Workstation allows for direct interaction with the Smart Platform to
allow for initial software loading, tuning of the scanner and sensors, diagnostics,
and monitoring. In order to proceed with platform or sensor setup, the Service
Workstation and the Smart Platform software must be activated. Once the Smart
Platform software is loaded in the BRAM of the end column boards, the content
has battery backup for several days, and the platform software can be repeatedly
restarted by means of the RESET button on MPRC, by the power down and power
up cycle, or by Service Workstation commands.
For the initial configuration and software loading of the Service Workstation and
the Smart Platform, please refer to the appropriate AccuRay Smart Platform System
Software Manual, 101760-xxx.
For subsequent start up, please refer to “Startup Options” on page 179.
Note: It is possible to run the Smart Platform software independent of the

Host. All procedures, except where specifically noted, can be
executed by local commands using the control panel and Service
Workstation.

Blank Page

5
Platform Tuning
Chapter 5 describes the activities required to set up and tune the scanning control
for the Smart Platform.
Section............................................................................................... Page
Platform Software Setup Checklist ............................................................... 70
Motor Drive Setup (ABB ACS-100) ............................................................. 72
Motor Controller Setup (Fincor and Lovejoy) .............................................. 79
Basic Tuning .................................................................................................. 83
Head Position Setup ...................................................................................... 91
Head Package Dimensions Setup .................................................................. 96
Automatic Edge-of-Sheet .............................................................................. 102
Motion Restriction Sensitivity ....................................................................... 106
Changing the Motion Restriction Sensitivity ................................................ 107
Standardize Off-Sheet Delay Setup ............................................................... 108
Other Host Setup Procedures ........................................................................ 110
101764-003 Platform Tuning 69


Platform Software Setup Checklist

Smart Platform software setup ensures efficient movement of the Smart Platform
head package and the correct positioning of the head package on the process sheet.
This checklist is a recommended sequence of steps to correctly set up the Smart
Platform.
❒ Use the Electronics Health Report to make certain there are no safety interrupts
which might impede the setup process.
❒ Check for alarms while tuning the frame.
❒ Set up the motor controller (page 79).
❒ Perform basic Smart Platform tuning–head position calibration and automatic
motor control tuning (page 83).
❒ Set up the Smart Platform position values (page 91). If required, set up select
positions in the host computer.
❒ Restart the communications between the Host computer and the Smart Platform
(required to download Host head positions to the Smart Platform).
❒ Head Package Dimension Setup (page 96).
❒ Set up the Auto Edge–of–Sheet (AEOS) detectors, if configured on the Smart
Platform (page 102).
❒ Set up the head motion restriction sensitivity if required by the installation site
(page 107).
70 Platform Tuning 101764-003


ENTER Frame Tuning (ft) Menu Selections

ft
NOTE: After modifying any of the instance variables,
UTILITY remember to save the data to diskette either using the exit
save commands within ft, or by doing a gstore to the
appropriate frame or io community later.
1 2
MODIFY DISPLAY
VALUES STATUS
1 2 3 4 5 6 7 8
CURRENT
SCANNER
POSITION
VALUES
1 CURRENT
SPEED
2
HEAD POSITION
MOTOR
CONTROLLER 3 CURRENT
CALIBRATION SCANNER
4 REVIEW
OPERATION
MOTOR 5
CONTROLLER
CALIBRATION CURRENT
6 SCANNER ENGINEERING
REQUEST LIST DISPLAY
SCANNER/SHEET
POSITION
SETUP CURRENT CURRENT
SERVO AEOS
STATUS VALUES
(if configured)
SCANNER
SPEED
SETUP
SCANNING
MONITOR
SCANNER
AUTO EDGE
SETUP
(if configured) 1 Scanning Monitor
2 Servo Global Data
3 Servo State Data
MANUAL 4 Servo Timing Data
SERVO 5 Servo Trajectory Data
CALIBRATION 6 Servo Tuning Data
7 Frame Data
8 Encoder Data
Figure 5-1 Menu Tree


Motor Drive Setup (ABB ACS-100)

General Description
The direction and speed of the AC motor which moves the sensor head package is
managed by a motor drive. It determines how much torque to apply as the head
package traverses the frame.
The ABB ACS-100 Motor Drive (part number 133853-001) is the replacement for
both the Fincor and Lovejoy motor controllers. It uses a removable digital control
panel (MDPanel) to set the various tuning parameters. Motor drive assemblies
shipped from Columbus, Ohio, arrive preprogrammed with the standard Smart
Platform setup. These settings should provide proper performance for all scanners
except Smart U-Frames. For Smart U-Frames, the values for Parameters 202 and
306 must be entered manually. Should any tuning parameters change, it will be
necessary to rerun the Motor Drive Tuning routine (ft) in the software.
Control Panel Functions
The MDPanel is the only access to the Motor Drive provided for setup and
diagnostics. It can be detached from the motor drive, but should only be removed
when the motor drive is in REMOTE mode. The MDPanel can also be used to copy
parameters from one motor controller to others. See “Downloading Parameters”
on page 76.
Figure 5-2 MDPanel


The push buttons, on the MDPanel, are used to navigate around a menu to give
access to the various tuning parameters. These parameters are organized into five
groups, 01 through 05. See Table 5-1 on page 74. Each group has three or more
subgroups. With the exception of the Smart U-Frame, all scanners should be able
to operate with ABB SP Default parameter values. These defaults have been stored
in the MDPanel to facilitate ease of setup.
The push buttons used in this application are:
• MENU
• ENTER
• UP/DN arrows
The two buttons to the left are not used. The LCD displays menu selections,
parameter values, and fault conditions. Appropriate parameter units are displayed
along with the values.
Coded alarms which appear on the display can be decoded using Table 5-2 on
page 78.
Motor Drive Parameters
The motor drive that is shipped with the frame will be programmed with the correct
tuning parameters. If the drive is replaced, the values should be checked against
the appropriate default values.
Failure to use the correct values will result in improper

frame operation, burn the windings of the motor, or
produce excessive torque.


Controller Vendor Smart Platform Smart U-Frame

Code Name Default Values Default Values Values
Group 01: ACTUAL VALUES AND STATUS
101 fref (Info Only) (Info Only) (Info Only)
102 Last Fault (Info Only) (Info Only) (Info Only)
103 Version (Info Only) (Info Only) (Info Only)
Group 02: MOTOR VALUES AND LIMITS
201 Unom 230 V 230 V 230 V
202 fnom 50 Hz 155 Hz 95 Hz
203 Inom 2.2 Amp 1.1 Amp 1.1 Amp
204 Nom Speed 1440 rpm 1800 rpm 1800 rpm
205 Imax 3.3 Amp 2.5 Amp 2.5 Amp
206 fmax 50 Hz 120 Hz 120 Hz
207 fmin 0 Hz 0 Hz 0 Hz
208 Dir Lock 1 1 1
209 Motor Noise 0 0 0
Group 03: DRIVE CONTROL
301 Stop 1 1 1
302 Ramp 0 0 0
303 Acc 5.0 sec 1.0 sec 1.0 sec
304 Dec 5.0 sec 0.5 sec 0.5 sec
305 U/f Ratio 1 1 1
306 IR Comp 10 VAC 5 VAC 6 VAC
307 DC Inj Time 0.0 sec 0.0 sec 0.0 sec
308 UCmax Control 1 1 1
Group 04: INPUT/OUTPUT
401 Al min 0% 0% 0%
402 Al max 100% 100% 100%
403 Ref min 0 Hz 0 Hz 0 Hz
404 Ref max 50 Hz 120 Hz 120 Hz
405 DI Config 1 1 1
406 Const speed 5 Hz 5 Hz 5 Hz
Group 05: SUPERVISION
501 Al Fault 0 1 1
502 flim 35 Hz 0 0
503 Param Lock 1 1 1
Note: Motor Drive assemblies shipped from Columbus, Ohio arrive

preprogrammed with the standard Smart Platform setup. For Smart
U-Frames, the values for Codes 202 and 306 must be entered
manually.
Table 5-1 Motor Drive Parmeters


Panel Operations
The panel display defaults to the Code 101 display of output frequency. Subsequent
pressing of the UP/DN arrow push buttons will alternate the display between the
output frequency and output current.
Moving Around the Menu
1. Press the MENU push button to show the menu group level of the last observed
parameter value.
2. Press the DN arrow push button to get to lower menu groups. It is a rotating
display buffer; so you will eventually get to where you want, even if you pick
the wrong direction.
3. When you get to the group you want, press ENTER to move into the subgroup.
The same rules apply within the subgroup.
4. At the desired subgroup, press ENTER to view the parameter value. Press and
release quickly, and the value only displays for a moment. Press it for a few
seconds, and the value will stay on the display.
5. Press MENU to get back to the submenu display.
Table 5-1 on page 74 shows the available menu selections.
LOCAL/REMOTE
The power-up default mode for the Motor Drive is REMOTE. All values can be
observed in REMOTE. However, values can only be changed when the Drive is in
LOCAL mode.
1. To put the Motor Drive in LOCAL, simultaneously press the MENU and
ENTER push buttons. Note that the LCD shows the new mode.
2. To go back to REMOTE, simultaneously press the MENU and ENTER push
buttons again.
Setting a Parameter Value
1. Go to the desired parameter menu location (see Table 5-1 on page 74).
2. Set the MDPanel to show LOCAL mode.
3. Press the ENTER push button until SET is displayed.
4. Use the UP/DN arrow push buttons to adjust the parameter to the desired value.
When the value is changed, the SET display will blink.
5. Return the MDPanel to REMOTE operations when done.


Downloading Parameters
This operation should only be used to program a new Motor Drive using an MDPanel
which already contains the desired parameter values.
Note: Make sure the MDPanel shows the LOCAL mode.
1. Press the MENU push button to get to the group display.
Do not execute the “-Fd-” menu selection. It will change

the Motor Controller to the ABB Drives factory settings,
not the settings established for ABB scanners.
2. Press the UP arrow push buttons until the display shows “-dL-”.
3. Press and hold the ENTER push button until the display starts to blink. When
the operation is complete, the display will revert back to the power-up display
of output frequency (Hz).
4. Return the control panel to REMOTE operation when done.


Uploading Parameters
This operation is used to prepare a new Motor Drive Panel unit with default
parameters from a Motor Drive that is known to have the correct operational
parameters installed.
Note: Make sure:

1. The configuration switch (S1) on the motor controller is at zero
(0).
2. The MDPanel is showing LOCAL mode.
1. Press the MENU push button to get to the group display.

2. Press the UP arrow push button until the display shows “-UL-”.
Do not execute the “-Fd-” menu selection. It will change

the Motor Drive to the ABB Drives factory settings, not
the settings established for the Smart Platforms.
3. Press and hold the ENTER push button until the display starts to blink. When
the operation is complete, the display will revert back to the power-up display
of output frequency (Hz).
4. Return the MDPanel to REMOTE operation when done.


Alarms and Fault Reporting

Code Description
CF 0 - CF 9 Position of configuration switch S1.
Certain parameters can be modified only when S1=0.
AL 1 Parameter upload/download failed.
AL 2 Operation not allowed while start is active.
AL 3 Operation not allowed in remote or local control.
AL 4 REVERSE button disabled. Parameter 208 (Dir Lock) is active.
AL 5 Panel START button disabled.
DI configuration is three-wire and D12 is open.
AL 6 Operation not allowed. Parameter 503 (Param Lock) is active.
AL 10 Overcurrent controller active.
AL 11 Overvoltage controller active.
AL 12 Undervoltage controller active.
AL 13 Reserved. Contact supplier.
AL 14 Reverse command attempted in remote control (REM), while parameter 208
(Dir Lock) is active.
AL 15 - AL 16 Reserved. Contact supplier.
FL 1 Overcurrent:
• Possible mechanical problem.
• Acceleration and/or Deceleration times may be too small.
FL 2 DC overvoltage:
• Input voltage too high.
• Deceleration time may be too small.
FL 3 ACS 100 overtemperature:
• Ambient temperature too high.
• Severe overload.
FL 4 Fault current: output earth fault or short circuit
FL 5 Output overload.
FL 6 DC undervoltage.
FL 7 Analog input fault. See parameter 501.
FL 8 Motor overtemperature. See parameter 502.
FL 9 Panel disconnected from drive in local control.
NOTE: If FL9 is active when the power is turned off, the ACS 100 will start in
remote control (REM) when the power is turned back on.
FL 10 Parameters inconsistent.
Check that Al min (fmin) is not greater than Al max (fmax).
FL 11* DC bus ripple too large.
Check supply.
FL 12 Reserved. Contact supplier.
FL 13 - FL 19* Hardware error. Contact supplier.
Full display Serial link failure.
blinking Bad connection between the control panel and the ACS 100.
Note: Faults (*) with a red blinking LED are reset by turning the power off
and on. Other faults are reset by pressing the START/STOP button.
Table 5-2 Motor Drive Alarms and Faults


Motor Controller Setup (Fincor and Lovejoy)

The direction and speed of the AC motor which drives the Smart Platform, is
managed by the motor controller, located in the end column of the Smart Platform.
The motor controller determines how much torque to apply when the head package
encounters resistance.
At initial power–up, before head position calibration or tuning, the Smart Platform
will move at 50 percent of its maximum speed whenever the JOG push buttons are
pressed. The maximum speed is determined by the FMAX adjustment on the motor
controller and this speed is used when moving off–sheet from a position out on the
scanner.
The motor controller will also affect the perceived tuning of the Smart Platform.
The actual velocity of the head package movement has a non–linear relationship
with the output request of the Smart Platform due to the dynamics of the motor
controller. Any changes to the motor controller adjustment will require retuning
of the software.
The procedure to correctly set up the motor controller requires you to manually
adjust the motor controller and alter instance variables in the Smart Platform
software using the ft utility.
Procedure
1. At the Service Workstation, run the ft utility by typing ft at the $$ prompt. The
screen shown in Figure 5-3 on page 80 will help you find your way through the
menu selections.
2. In the ft main menu, select MODIFY Values, selection 1.
3. Select Manual Servo Calibration, selection 6, from the MODIFY Values menu.
The Manual Servo Calibration screen is shown in Figure 5-3.


*** MANUAL SERVO CALIBRATION ***

Variable Name Description Current Value
1: Accel Nominal acceleration. 40.59
2: vmin Minimum speed necessary to move head. 3.85
activeVmin Current minimum speed value in use. 3.85
3: vmax Maximum allowed speed. 40.55
4: vdb Velocity deadband for DDC control. 1.00
5: Kp DDC proportional gain term. 0.250
6: Ki DDC integral gain term. 0.010
7: ddcExcessiveErrorPct Excessive error percent for DDC control. 25.00
8: ddcRestrictedMotionPct Restricted motion percent for DDC control. 50.00
9: vminTune Vmin self-tuning algorithm active. OFF
10: vminFilterFactor Exp. filter factor for vmin self-tuning. 0.33
11: MCslope Motor controller slope. 0.09
12: MCoffset Motor controller offset. 18
13: MCjogCommand DAC output for jogging the frame. 128
14: MCfastTuneDAC Motor controller tuning FAST DAC output. 190
15: MCslowTuneDAC Motor controller tuning SLOW DAC output. 80
16: xdb Position deadband for HOMING control. 0.95
TO MODIFY A VARIABLE ENTER ITS NUMBER NOW
(r to redisplay, q to quit, Q to exit):
Figure 5-3 Manual Servo Calibration Screen in ft.

4. Set the value for MCjogCommand to 128.
5. Mark two positions on the frame which are 150 cm (60 in.) apart.
6. Use the JOG push buttons to move the head between the marked positions,
adjusting FMAX on the motor controller until the time to traverse the positions
is between six and 10 seconds.
For long frames (greater than 8 meters), the faster time may be required to
successfully accomplish frame tuning.
7. Jog the head, adjust V/F so that the head can be manually stopped as it traverses
without undue effort. Note that this is being done at the jog speed which is
roughly 15 cm/sec (6 in./sec).
Higher scan speeds will require more force to stop and lower scan speeds will
require less force.
8. Manually force the head carriage to move from a stopped position.
9. Adjust the BOOST potentiometer so that significant force is required to make
it move.
10. Ensure that the motor does not heat up when in the off-sheet position (too much
boost can cause a stopped motor to overheat).
11. Exit the ft utility, type q and press RETURN when requested to save the
variables changed in this procedure to the current .ini files.


Mounting Screws
Motor Controller Mounting Sled

(Controller Cover Removed)
Smart Platform
Drive-side end column
Figure 5-4 Location of the Motor Controller in the Smart Platform End Column


ACCEL
(zero)
DECEL
(zero)
JOG
(zero)
BOOST
(Slow Torque)
(25% to 75%
of Max)
(see text)
V/F
(Motor Torque)
(Approximately
10% of max)
Motor Controller Circuit Board

MCAL
(zero)
FMAX
(Max Speed)
(Approximately
50% of max)
Figure 5-5 Adjustments to the Motor Controller


Basic Tuning
The basic tuning portion of Smart Platform Setup will calibrate the position encoder
and tune the controlling software (servo object) for the Smart Platform drive motor.
Head position calibration will be achieved by entering a position measurement into
the ft utility at the Service Workstation. The calibration utility will determine the
measured position on the Smart Platform.
The servo tuning is an automated routine that measures the response of the Smart
Platform to a series of velocity targets initiated by the controlling software. The
servo software object is then calibrated to the response of the motor controller setup.
The response is affected by the tuning of the motor controller hardware, so the
Motor Controller Setup procedure must be performed before basic tuning.
This procedure requires you to jog the Smart Platform head package and take one
dimension measurement on the Smart Platform and enter it at the Service
Workstation. The automated master controller motor controller tuning portion of
this procedure will move the head package to several positions on the Smart
Platform.
Before proceeding with this phase, make certain the Far

Limit Switch has been mechanically adjusted to prevent
the head package from hitting an obstruction, such as
the machine ropes.
Procedure
1. At the Service Workstation, start the ft utility, by typing ft at the $$ prompt.
2. In the ft main menu, select MODIFY Values, selection 1.
3. Select Head Position and Motor Controller Calibration, selection 1, from the
MODIFY Values menu.
The ft utility will display the current tuning values as shown in Figure 5-6 on
page 84.


*** HEAD POSITION CALIBRATION ***
The CURRENT head position slope is : 0.010000

The CURRENT head position offset is : 1.725000
The CURRENT scanner home travel limit is: 17.625000
The CURRENT scanner far travel limit is293.075000
This frame has auto edge of sheet (AEOS):

The HOME edge detector offset is: 35.000000
The FAR edge detector offset is: 19.500000
Please enter the frame type or q to quit;

1 for 700;
2 for 1200 or Dual Rail U-Frame;
3 for Single Rail U-Frame; Step 4
Please enter the customer units for head position (1 = cm; 2 = inch; q to quit);2
Figure 5-6 Head Position Calibration – Initial Display (Example)

4. Enter the frame type. For example, enter “2” for the SP1200, Reflection
Scanner, or Smart Dual Rail U-Frame. Enter a “1” for the SP700. Enter a “3”
for the Smart Single Rail U-Frame.
5. After selecting frame type 1200, choose the units to be used for the head position
calibration, as shown in Figure 5-6.
Select 1 for centimeters, or select 2 for inches.
Note: Initially, the Smart Platform is configured with the customer units
defined as centimeters. If it is necessary to change the customer
units to inches, all of the Smart Platform dimension variables must
be converted to inches.


6. When requested by ft, use the JOG push buttons to move the Smart Platform
head package to the home limit switch.
The home side limit switch is activated when the scanning head will not jog
further in the home end column direction.
7. Measure the distance from the home end column to the edge of the carriage
wrap–around assembly as shown in Figure 5-7.
Record the measurement in the customer units chosen in Step 4.
Home End Column
Head package
at mechanical
stop
Measure this distance

Figure 5-7 Head Position Calibration Measurement


8. When requested by the ft utility, enter the measurement taken in Step 7, as

shown in Figure 5-8.
The utility will display the computed value for the distance between the end
column and the measurement window center line, based on the measurement
entered. If the values do not seem reasonable, repeat this step.
Jog the frame to the HOME limit switch;

PUSH the head against the mechanical stop and
measure the wraparound carriage distance;
Enter the customer units value of this position => 5.25 Step 7
NOTE: The following measurements are with respect to the head center line
The MEASURED home travel limit is : 17.625000 units
: 1600.000000 counts
The DESIRED home travel limit is : 17.625000 units
Do you wish to repeat the HOME limit setup? (y or n):n
Figure 5-8 Head Position Calibration Screen

9. The utility will ask whether you want to use automatic (a) or manual (m)
determination of the far limit switch position. The preferred method is manual.
In manual, you should first force the head into the far mechanical stop position
after reaching the limit switch, then, press RETURN.
The utility will display the measured value, in customer units, of the current
position of the head package, shown in Figure 5-8. If acceptable, press return.
If the value does not seem reasonable, repeat this step.
If automatic, jog the Smart Platform head package to the far limit switch, using
the JOG push buttons. When the head package has reached the limit switch,
wait one second and then return the head to the home end and place in remote.
10. The utility provides the option of establishing a process centerline point. The
utility will then ask if you want to use the machine centerline to determine setup.
For all but aseptic applications, you should answer no (n). The process
centerline setup enables the system to establish reasonable scan limits and speed
apart from further setup and control by a host computer. A “no” (n) answer
advances you to the next step. A “yes” answer (y) answer asks you to jog the
head to the position on the platform which represents the centerline of the
process. Then, press the RETURN key. In either case, a final summary of the
head position calibration procedure will be displayed as shown in Figure 5-9
on page 87.


11. To save the head position calibration values determined in this procedure, press
RETURN when prompted by the utility as shown in Figure 5-9. There is a
separate prompt for io.ini, frame.ini, and appl.ini.
The new calibration values will be saved to the current .ini file so that they will
be available when the Smart Platform is restarted.
Since the head position calibration tuning has been changed, it is necessary to
reload the Host computer head positions with the Smart Platform, by using the
PMMRLD command.
The NEW head position slope is : 0.010000

The new head position offset is: 1.625000
Scanner’s home travel limit has been changed to 17.625000 units.
Scanner’s far travel limit has been changed to 293.145000 units.
Scanner’s maximum speed has been changed to 15.891772 units.
Scanner’s on–sheet speed has been changed to 5.959414 units.
PmmFrame has been recalibrated to new max limits.
Servo’s minimum speed (vmin) has been changed to 0.720715 units.
Servo’s maximum speed (vmax) has been changed to 15.891712 units.
Servo‘s maximum acceleration (Accel) has been changed to 4.592000 units.
Servo‘s position deadband (xdb) has been changed to 0.639990 units.
EdgeDetector’s directional hysteresis has been set to: 0.160000 units.
Enter new file path name OR
(ret) to save to ”/ss01/clm/frame.ini” OR
”q” to quit.
=>
Frame graph was successfully saved to file ”/ss01/clm/frame.ini”.
Enter new path name OR
(ret) to save to ”/ss01/clm/io.ini” OR
”q” to quit.
=>
Enter the new file path name OR
<ret> to save to ”/ss01/clm/appl.ini” OR
”q” to quit.
=>
Step 10
NOTE: Successful completion of head position calibration
requires (re)calibration of the Motor Controller;
This function will be performed next...
Figure 5-9 Head Position Calibration Summary Display


Note: Make sure the head is near but not on the Home Limit Switch prior
to Step 12.
12. Press RETURN to continue or press a to abort.

If return is selected the system will respond with the message
*** AUTOMATIC SERVO CALIBRATION ***
13. The system will display the following message:
Motor controller tuning will cross the sheet edges, do you
wish to continue? (y or n) (If a sheet break is present this step will
be skipped.)
Note: If the head crossing the sheet edge will create a problem, abort the
procedure. Wait until there is a sheet break before proceeding.
14. Place Frame Control in Remote and press RETURN to continue.

The Motor Controller Tuning screen will be displayed, as shown in the example
in Figure 5-10 on page 89.
The scanning carriage will move in the off–sheet direction and search for its
home position. It will then begin a series of movements across the Smart
Platform, taking velocity and distance measurements at certain times. After
appropriately 30 seconds, the utility will finish the motor controller calibration.
You can terminate the Automatic Controller Tuning at any time by typing “a”
at the keyboard, or placing the Smart Platform in LOCAL control at the control
panel.
Note: On scanners less than 2.5 meters long, it may be necessary to

reduce the SLOW and FAST JOG DAC outputs to keep the head
from tripping the far travel limit switch during the motor controller
tuning.
15. When motor controller tuning is complete, the utility will display a banner
across the middle of the display. The display prompts you to accept the tuning
results, “y” or “n”. Answer “y” unless the new slope and offset values seem
incorrect. A summary of the new motor controller calibration values is shown
16. In order to fully implement the head position calibration procedure, it will be
necessary to restart the Smart Platform as a final step. To do this, exit the ft
utility and type reset at the $$ prompt.


17. Establish a correct minimum velocity.

Because of the action by the servo to keep increasing the output until there is
movement, it is not likely that there will be situations where the head will
actually stall. activeVmin is only changed if the vminTune flag is set. Making
sure that the system has established a reasonable activeVmin before turning
off the vminTune flag is important because it allows the servo HOMING action
to proceed quicker if a more correct starting point is used. Once a reasonable
activeVmin has been established, the value should be written into the vmin
field and saved using the gstore utility. This will establish the correct
activeVmin at the next system restart.
Carriage return to continue or “a” to abort...

”a” to Abort [ MOTOR CONTROLLER TUNING ]
DAC Event Forward Forward Reverse Reverse
Output Duration Time Of Position Time Of Position
Start 80 5.000 12093.015 12339
Accelerate Slow 80 1.000
Slow Sample One 80 1.000 12095.016 [1] 13677 0.000 [5] 0
Slow Sample Two 80 12.000 0.000 [2] 0 0.000 [6] 0
Accelerate Fast 190 1.000
Fast Sample One 190 1.000 0.000 [3] 0 0.000 [7] 0
Fast Sample Two 190 4.500 0.000 [4] 0 0.000 [8] 0
TurnAround 190 1.000
Fast Stop 190 1.000 Old Slope 0.087 New Slope 0.000
Decelerate Slow 80 1.000 Old Offset 18 New Offset 0
|------------------------------------------------------------------------|
| > |
H O h--------------------------------------------f F
Tuning State CRUISING_SLOW_FORWARD_TO_SAMPLE_TWO Timer 3.000
Current: Time 12098.016 Position 15720 FORWARD DAC 80
Initialization: Time 12087.619 Position 9017 Elapsed Time 10.397
Motion Threshold Time 99.900 Counts 100
Motion: Timer 10.400 Detected FALSE
Positions: H = 3430 O = 9057 h = 12078 f = 42291 F = 54725
Limits: Reverse FALSE Forward FALSE
Figure 5-10 Automatic Motor Controller Tuning Screen


18. To use the motor controller calibration values determined in this procedure,
press RETURN when prompted by the utility, as shown in Figure 5-11. The
new calibration values will be saved to the current .ini file so that they will be
available when the Smart Platform is restarted.
The ft utility will return to the MODIFY Values menu.
*** AUTOMATIC SERVO CALIBRATION ***

The following servo tuning changes are being implemented:
Motor controller slope of 0.139 is being changed to 0.139
Motor controller offset of 10 is being changed to 11
Servo minimum speed of 0.721 is being changed to 0.989
Servo maximum speed of 15.892 is being changed to 15.801
Scanner maximum speed of 15.982 is being changed to 15.801
Enter new file path name OR
(ret) to save to ”/ss01/clm/frame.ini” OR Step 13
”q” to quit.
=>
Frame graph was successfully saved to file ”/ss01/clm/frame.ini”
Carriage return to continue...
Figure 5-11 Motor Controller Servo Calibration Summary


Head Position Setup

This section defines specific head position locations. See Figure 5-12 on page 93.
The position variables are listed below.
Garage Position (OFF)
The Garage Position is the position on the Smart Platform, next to the process,
where maintenance is performed. The entered distance should be the smallest of
the Host positions, as measured from the home end column.
If personal safety and service access needs dictate, it is possible to place the off–
sheet position adjacent to the far column end of the platform. In this case, leave
the standardize position at the home end if possible and note that when going on–
sheet, the heads will traverse the entire platform length from the far end to the home
end in order to start its scan.
Standardize Position (STDZ)
The Standardize Position is the position where sensor standardization occurs. This
position typically is the same as the off sheet position and should never be close
enough to the sheet edge so that the far edge detector sees the sheet edge. The
entered distance should be less than the value for the Minimum Home EOS Position.
Normally the off–sheet and standardize positions are identical because this allows
the automatic check sample sequence to be extended after standardize without
moving the head to a new position and enhances accuracy.
Minimum Home Measure Position (LHEOS)
This position defines the home position of the maximum scan width, and the
minimum limit for the Current Home Scan Limit. The Smart Platform will never
scan outside of the minimum measure position. This value should be greater than
those for the Garage Position and the Standardize Position. This position is called
the Home Measure Limit.
Current Home Scan Position (KHEOS)
This position is the current home side scan limit for the present sheet width. This
value will never be less than the Minimum Home Measure Position. This position
is called the Home Scan Limit.
Default Single Point Position (SPPOS)
This is the default single–point measurement position, when the Smart Platform is
placed in the single–point mode. The entered value must be between the Current
Home Scan Position and Current Far Scan Position.


Current Far Scan Position (KFEOS)

This position is the current far side scan limit for the present sheet width. This value
will never be greater than Maximum Far Measure Position. This position is called
the Far Scan Limit.
Maximum Far Measure Position (LFEOS)
This position defines the far position of maximum scan width, and the maximum
limit for Current Far Scan Limit. The Smart Platform never scans outside of the
Maximum Measure Position. This position is called the Far Measure Limit.


Home End Far End

Column Process Sheet Column
1
2
3
4
5
6
7
Figure 5-12 Smart Platform Positions at the Host Computer

1. Garage Position (OFF)
2. Standardize Position (STDZ)
3. Minimum Home Measure Position (LHEOS)
4. Current Home Scan Position (KHEOS)
5. Default Single Point Position (SPPOS)
6. Current Far Scan Position (KFEOS)
7. Maximum Far Measure Position (LFEOS)


Notes about LHEOS and LFEOS

(Scanning Measurement Limits)
The variables LHEOS and LFEOS define the sheet’s measure limits at the maximum
possible trim positions of the process. This then defines the farthest positions which
the measurement heads can achieve during scanning operations. As a result these
variables define the width and location of all system databoxes.
On multi–frame applications, all frames must be identically aligned with respect to
the physical process. Since sheet shrinkage is a very nonlinear function, it is not
recommended that any attempt be made to compensate for shrinkage by misaligning
the frames. Proper compensation for sheet shrinkage can only be accomplished via
algorithmic means. See Figure 5-13.
Max Trim
LFEOS LHEOS
Frame 2
Measure Limits
Frame 1
Measure Limits
Center of
Sheet
Figure 5-13 Limits for Multiple Frame Installations
Procedure for LHEOS and LFEOS

1. Determine the physical center line of the process relative to the Headbox at
each frame location. Note that the center line of the rolls in any area of the
machine may not be the center line of the process.
2. The maximum trim locations should be determined by measuring equal
distances from the center line determined above to each edge of the possible
sheet run.
3. JOG or otherwise move the head package until the center line of the sensing
windows is directly aligned with each of the maximum trim locations
determined above. Permanently mark the frames to identify the maximum trim
locations. These marks will make it easier to check or set up these locations
during maintenance operations.
4. Record the head position while the head package is at each of the marked
locations. Enter the recorded position into LHEOS and LFEOS, as specified
for your system.


Procedure for Determining Position Values

Mark the locations of the machine center line, the Minimum Home Measure
Position, and the Maximum Far Measure Position on the Smart Platform for future
reference.
Note: If you have trouble using the Jog push buttons on the Smart Platform
control panel because the system is too responsive, slow down the
jog speed using the Frame Health Page Report.
1. Select the Frame Health Report. If necessary, refer to “Operation of the Sensor
Health Pages” on page 116.
2. Use the JOG push buttons on the Smart Platform end column to move the head
package to the desired position.
3. Record the current head position as displayed on the Health Report.
4. Repeat Steps 2 and 3 for each of the fixed frame positions.
5. Enter values in customer units in the appropriate data fields of the Health Report.
6. Remember to do a gstore to make changes permanent.
Frame Health Report

ABB Process Automation FWS170.009 RELEASED 01-31-96 11:44:27
SP Release: SP280.2 Page 1 of 1
Frame Ctrl From: WORKSTATION Safety Intr: Reset
Head Command: OFFSHEET Safety Alarms: No
Frame Type: SP 1200 Active Alarms: NO
SCANNER SETUP
Max Speed CU/SEC 11.81 ** Home Travel Limit CU 20.38
On Sheet Speed CU/SEC 5.21 Garage Position CU 26.40
Scan Speed CU/SEC 3.23 Stdz Position CU 26.40
On Sheet Time SEC 50 Home Measure Limit CU 38.79
Off Sheet Time SEC 120 Home Manual Scan Limit CU 49.70
Far Manual Scan Limit CU 247.43
Far Measure Limit CU 258.67
** ENTRY NOT PERMITTED ** Far Travel Limit CU 284.88
Power Shelf Temp ˚C 24.00
Motor Ctrl Temp ˚C 22.59
Sheet Break FALSE
Motor Overload FALSE Encoder SYNCHRONIZED
Beam Air Flow Alarm FALSE Head Position CU 26.33
Chiller 1 FLOWING C Position Error CU 0.35
Chiller 2 FLOWING o Servo Veloc CU/SEC 0.00
F Heads Split NO Avg DDC Corr 1.00
m
r BW Shutter CLOSED Home Scan Limit CU 49.70
p
a Ash Shutter NOT CLOSED u
m
t
e Far Scan Limit CU 247.43
e
r InTransit NO
Motor Ctrl Output DAC 0 Mtr Ctrl Slp 0.139
MC Direction FORWARD Mtr Ctrl Off CU/SEC 13
MC Run/Stop RUN Min Velocity CU/SEC 1.170
ESC F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 PGUP PGDN
EXIT HELP ALARM DATA SETUP STDZ SMPCK CALIB PRTSC PRVPG NXTPG
Figure 5-14 Frame Health Report with Scanner Setup Panel


Head Package Dimensions Setup

The sensor head package dimensions are used to control the orientation of the
window over the sheet as the head moves through its various sequences. The
variables used for this purposes can be manipulated to accomplish a variety of head
behavior patterns as the head moves from off–sheet to a scanning condition. This
section contains information about the locations of these variables and a procedure
for determining their values. The head package dimensional variables are defined
below. Two basic equations deal with bringing the head on–sheet, depending
whether auto edge of sheet is turned on or not:
Auto Edge of Sheet Turned Off:
Prepare to measure position = homeScanLimit + homeHeadClearance −
homeWindowClearance + curlDist + positioningSafetyFactor
Auto Edge of Sheet Turned On:
Prepare to measure position = homeEOS + homeHeadClearance + curlDist +
positioningSafetyFactor
Definition of Head Package Dimensions
Table 5-1 Head Package Dimensions
homeHeadClearance This variable represents the distance between the
home–side edge of the sensor head package and the
measurement center line. Its value will depend on
how far beyond the home edge of the sheet the head
must come before starting the Prepare To Measure
activity. In any event, it must always be larger than
the homeWindowClearance.
farHeadClearance This variable represents the distance between the
far–side edge of the sensor head package and the
measurement center line. The variable only comes
into play when the head must enter the prepare to
measure position from the far side of the scanner. In
that case, it will have the same function as the
homeHeadClearance. When it is used, it must be
larger than the farWindowClearance.
homeWindowClearance This variable represents the distance, on the home–
side of the head package, from the measurement
center line to the edge of the largest sensor window
in the head package. The window radii will range
from approximately 0.5 in. for a Smart Ash sensor
to 2.5 in. for a HemiPlus sensor (see Figure 5-15).
(continued on next page)


Table 5-1 (continued)

farWindowClearance This variable represents the distance, on the far–side
of the head package, from the measurement center
line to the edge of the largest sensor window in the
head. The window radii will range from
approximately 0.5 in. for a Smart Ash sensor to 2.5
in. for a HemiPlus sensor (see Figure 5-15).
curlDist This variable represents the additional distance that
the heads will travel when first coming on–sheet to
the prepare–to–measure position to assure that sheet
contacting sensors, such as caliper, are fully on–
sheet before making contact. The heads will then
back up to the Current Home EOS Position to start
scanning. If desired, the entire prepare-to-measure
positioning can be accomplished with the
homeHeadClearance dimension, leaving the
curlDist at its default value of 0.1 units.
positioningSafetyFactor This variable represents the additional distance that
the heads will travel when first coming on-sheet to
the prepare-to-measure position to assure that sheet
contacting sensors, such as caliper, are fully on-
sheet before making contact. The head will then
back up to the current homeScanLimit to start
scanning. If desired, the entire prepare-to-measure
positioning can be accomplished with the
homeHeadClearance dimension, leaving the
curlDist at its default value of 0.1 units.
The locations of these positions on a Smart Platform sensor head package are shown


farWindowClearence
homeWindowClearence
Measurement
Window
Center Line
homeHeadClearance
farHeadClearance
Figure 5-15 Location of Head Package Measurements


Determining and Entering the Head Dimensions

Refer to Table 5-2 on page 100 and Figure 5-16 on page 101.
1. Split the sensor heads, using one of the head split switches. Head split switches
are located in the drive end and idler end columns.
2. Measure and record the homeHeadClearance and the farHeadClearance (in
customer units) from the Smart Platform head package.
3. Enter the values for homeHeadClearance and farHeadClearance into the
Frame Health Report. Refer to Figure 5-16.
homeHeadClearance and farHeadClearance assist the servo in making sure
the head is sufficiently inside the sheet before measuring. These dimensions
can be adjusted instead of curlDist to suit a desired head position during Prepare
to Measure operations.
4. Determine the values for farWindowClearance and homeWindowClearance
from Figure 5-15 on page 98. Table 5-2 on page 100 gives typical measurement
area diameters for each sensor.
5. Divide the value for the largest sensor beam diameter by 2 to get the
farWindowClearance and homeWindowClearance.
6. Enter the resultant number into the HEAD SETUP section of the Frame Health
Report. Refer to Figure 5-16.
7. Exit the Health Report program.
8. Use the gstore procedure to save the changes made on the Frame Health Report.
Note: The diameters given in Table 5-2, define the nominal dimensions of
the various sensor measurement beams. Each sensor has its own
unique tolerance characteristics as the beam encroaches over a
sheet edge. These characteristics will govern, in part, how close
the measurement centerline may be brought to the sheet edge. For
example, a GT Caliper probe may not go beyond the edge. On the
other hand, a HemiPlus IR beam can be as much as halfway over
the edge. Check each sensor’s technical manual for that sensor’s
tolerance.


Table 5-2 Sensor Window Diameters

Measurement Beam
Diameter
Sensor Type Sensor Model in. cm
Basis Weight TLK–5 2.1 5.33
TLK–8 2.1 5.33
TLK–9 2.1 5.33
TLS–1 2.5 6.35
TLP–1 1.0 2.54
STLK* 0.59 1.5
STLP* 0.59 1.5
IR Moisture MIR–212 2.5 6.35
DIR–212 2.125 5.40
Microwave any -- --
Moisture
Ash TLXR 1.0 2.54
STLXR 0.59 1.5
Caliper any 2.0 5.08
Gloss any -- --
OptiPak any -- --
Smoothness any -- --
*Cross Machine Direction Only


Frame Health Report

INTEGRATION LOAD SP Release: SP280.2 Page 1 of 1
DEVEL-1 Frame Ctrl From: END COLUMN Safety Intr: RESET
REEL Head Command: OFFSHEET System Alarms: NO
Frame Type: SP 1200 Active Alarms NO
HEAD SETUP AUTO EDGE OF SHEET

Curl Distance CU
AEOS State 0.10 ON
Home Head Clearance CU
** Home Det Offset 2.70 CU 16.83
Far Head Clearance CU
** Far Det Offset 2.70 CU 10.75
Home Window Clearance CU
EOS Deadband 2.60 CU 2.00
Far Window Clearance CU
Max Edge Change 2.60 CU 100.00
Home Edge Track CU 2.00
Far Edge Track CU 2.00
**IF CHANGED, RESET FRAME MICROCONTROLLER
Power Shelf Temp C° 26.83
Sheet Break FALSE Motor Ctrl Temp °C 25.44
Motor Overload FALSE
Beam Air Flow Alarm FALSE Encoder SYNCHRONIZED
Chiller 1 FLOWING Head Position CU 29.92
Chiller 2 FLOWING Position Error CU -0.39
Heads Split NO Servo Veloc CU/SEC 0.00
BW Shutter CLOSED C Avg DDC Corr 1.00
F Ash Shutter Home Scan Limit CU 85.00
r CLOSED o CU
m Home EOS 57.89
a Far EOS CU 236.82
m p
u Far Scan Limit CU 230.23
e InTransit NO
t
e Mtr Ctrl Slp 0.170
Motor Ctrl Output DAC 0 r Mtr Ctrl Off CU/SEC 22
MC Direction REVERSE Min Velocity CU/SEC 1.616
MC Run/Stop RUN
Esc F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 PGUP PGDN

Figure 5-16 Head Setup Using the Frame Health Report

Press the F6 key until the desired setup panel appears on the Health Report.


Automatic Edge-of-Sheet
The Automatic Edge-of-Sheet (AEOS) option available on the Smart Platform
allows the sensor head package to closely track the edge of the process sheet, and
to respond to changes in the width of the process sheet. AEOS is made possible by
mounting an infrared detector on the home and far edges of the head package.
This section contains guidelines for the setup of AEOS and a procedure for entering
the values in the Smart Platform.
The variables necessary for set up of AEOS are described below.
maxEdgeChange This variable represents the maximum amount the sheet edge position
is allowed to change before interpreting the edge change as a sheet
break. All edge changes which are within this value, but greater than
EOSDeadband are considered valid and sent to the Host computer.
EOSDeadband This variable represents the distance the sheet edge is allowed to
wander before a valid edge change to the Host is triggered.
homeEdgeTrack This variable represents the target distance from the home edge of the
window in the head package to the home edge of the sheet. See note
on page 99.
farEdgeTrack This variable is the target distance from the far edge of the window
in the head package to the far edge of the sheet. See note on page 99.
homeDetectorOffset This variable is the distance from the measurement window center
line to the center of the home edge sheet detector.
farDetectorOffset This variable is the distance from the measurement window center
line to the center of the far edge sheet detector.
allowSecondEdgeErrMsg This variable is designed to allow or disallow an error message in “pe”
when the far edge detector sees a threading rope which is close to the
far sheet edge. If the flag is set to a 1, then the system will report that
it has found a new edge. If the flag is set to a 0, its normal default
value, the system will assume the new edge was a threading rope and
ignore the occurrence. If the system performance requires that the far
edge detector see the threading ropes in order to get close to the sheet
edge, this flag should be set to 0.
allowEdgeOutsideLimits This variable is used to permit the ignoring of false home edge
detection while the head is coming on-sheet. This situation may occur
on a Smart Platform Reflection Scanner when there is a piece of the
paper machine structure which can be seen by the edge detectors while
coming on-sheet. For this to be effective, the actual edge of the sheet
must be at a distance from the interfering structure that is at least the
separation between the two edge detectors. This flag is defaulted to
a 1, which will make the head acknowledge the false edge, and if it is
outside the homeMeasureLimit, will position the window centerline
so that is is just inside the homeMeasureLimit. By making the flag
a 0, the detectors will ignore the false edge and proceed to the
predefined prepare to measure position.


These measurement relationships are shown in Figure 5-17 on page 103.
Home Edge of Sheet Far Edge of Sheet
EOSDeadBand EOSDeadBand
or or
maxEdgeChange maxEdgeChange
homeEdgeTrack farEdgeTrack
SENSOR SENSOR
HEAD Edge Detectors HEAD
PACKAGE PACKAGE
Edge Detector Edge Detector
homeDetectorOffset farDetectorOffset
(L1) (L2)
Measurement Measurement
Window Window
Center Center
Line Line
Sheet Width
Figure 5-17 Automatic Edge-of-Sheet Position Measurements
Setup Guidelines
When the Smart Platform scans near an edge, the scan limits will change only if
the projected new scan limit will be outside the EOSDeadband value of the current
scan limit.
It is important that all of the setup parameters be entered in the same customer units.


Do not make either homeEdgeTrackingDistance or farEdgeTrackingDistance

smaller than the value for xdb located on the Frame Health page, setup panel
number 3. If either of these tracking variables is made too small, the Smart Platform
may position part of the window off the sheet edge, resulting in an increase in the
dwell time at the edges. As the EOSDeadband is made smaller, the Smart Platform
will report a larger number of scan limit changes.
The relationship between the calculated scan limits and the detected edges is as
follows:
homeScanLimit = homeEOS + farWindowClearance + farEdgeTrackingDistance + EOSDeadband
farScanLimit = farEOS - farWindowClearance - farEdgeTrackingDistance - EOSDeadband
The tracking distance variables should be set such that the scan limit positions allow
the edge detectors to see the sheet edge. If the tracking distance is larger than the
detector offset value, the head will not move smoothly at the sheet edge. In general,
the tracking distances should meet the following inequality:
(Detector Offset - Window Clearence) > (Tracking Distance + EOSDeadband + xdb)
Entering AEOS Setup Parameters

Based on the previous guidelines, the following procedure will show how to enter
the AEOS setup values into the Smart Platform, using the ft utility.
The values for homeDetectorOffset and farDetectorOffset can be measured on
the head package. The other values must be based on the desired performance of
the AEOS feature.
Procedure
1. At the Service Workstation, access the Frame Health Report. Refer to Figure
5-18 on page 105.
2. Enter values, in customer units, for the following variables:
AEOS State
Home Det Offset
Far Det Offset
EOS Deadband
Max Edge Change
Home Edge Track
Far Edge Track
3. Reset the microcontroller to activate the changed offsets.
Use the command: uc_reset -f 0x1f
4. After about 30 seconds, put the platform in remote mode to synchronize the
encoder.
5. Put the platform in the on–sheet mode to resume normal operation.


Frame Health Report

Frame Type: SP 1200 Active AlarmsNO
HEAD SETUP AUTO EDGE OF SHEET

Curl Distance CU 0.10 AEOS State ON
Home Head Clearance CU 2.70 ** Home Det Offset CU 16.83
Far Head Clearance CU 2.70 ** Far Det Offset CU 10.75
Home Window Clearance CU 2.60 EOS Deadband CU 2.00
Far Window Clearance CU 2.60 Max Edge Change CU 100.00
Home Edge Track CU 2.00
Far Edge Track CU 2.00
**IF CHANGED, RESET FRAME MICROCONTROLLER
BW Shutter CLOSED C Avg DDC Corr 1.00
F Ash Shutter CLOSED Home Scan Limit CU 85.00
r o
m Home EOS CU 57.89
a Far EOS CU 236.82
m p
u Far Scan Limit CU 230.23
e InTransit NO
t
MC Direction REVERSE Min Velocity CU/SEC 1.616
MC RUN/STOP RUN

Figure 5-18 AEOS Setup on the Frame Health Report


Motion Restriction Sensitivity

The Smart Platform can be set up to respond with varying degrees of sensitivity to
conditions which prevent or impede movement of the head package.
When the restriction exceeds the defined sensitivity, all drive output ceases and
sensor shutters are closed until corrective action can be taken to clear the condition.
An error message is also sent to the Host computer to notify it of the condition.
The desired sensitivity will depend on the setup of the motor controller and the site
requirements for stopping the head package when an obstruction is met.
Obtaining the correct sensitivity is a matter of adjusting two parameters:
ddcExcessiveErrorPercent, which has an inverse relationship to sensitivity, and
ddcMotionRestrictionPercent, which has a direct relationship to sensitivity. Table
5-3 lists the sensitivity parameters and examples of values to reach desired
sensitivities. Any value between 0 and 100 may be used. Experimentation will
determine the best values for the site.
Table 5-3 Example of Motion Restriction Sensitivity Values
Desired Sensitivity
low medium high default
ddcExcessiveErrorPercent 95 90 80 100
ddcMotionRestrictionPercent 5 20 50 0
Note: Motor drive response to restrictions is also influenced by the motor

controller pot adjustment for torque. High settings of the boost and
V/F adjustments will alter the values given in Figure 5-19 on
page 107.


Changing the Motion Restriction Sensitivity

Choose the desired sensitivity from Table 5-3 on page 106. The values can be
entered by using the Frame Health Report. Refer to Figure 5-19.
Frame Health Report

Frame Ctrl From: WORKSTATION Safety Intr: RESET
Head Command: OFFSHEET System Alarms:NO
Frame Type: SP 1200 Active AlarmsNO
SERVO SETUP
Acceleration CU/SEC 3.4732 DDC Proportional Gain 0.25
Position Deadband CU 0.3000 DDC Integral Gain 0.01
Minimum Velocity CU/SEC 1.1696 DDC Excessive Error % 100.00
Maximum Velocity CU/SEC 15.6761 DDC Restricted Motion % 0.00
MC Jog Command DAC 128 DDC Vmin Self-tuning ON
MC Slow Tune Speed DAC 80
MC Fast Tune Speed DAC 190

F BW Shutter CLOSED C Avg DDC Corr 1.00
r Ash Shutter NOT CLOSED o Home Scan Limit CU 85.00
a m Home EOS CU 57.89
m p Far EOS CU 236.82
e u Far Scan Limit CU 230.23
t InTransit NO
MC Direction FORWARD Min Velocity CU/SEC
MC RUN/STOP RUN 1.616

Figure 5-19 Setting Up Motion Sensitivity with the Frame Health Report
Press the F6 key until the desired setup panel appears on the Health Report.


Standardize Off-Sheet Delay Setup

At times there are large temperature differences between the off-sheet position and
where the head package is over the process. These temperature differences can
cause measurement problems if the head has been off-sheet long enough to cool.
Under this situation, it is not appropriate to initiate a standardize before going back
on-sheet, as this will introduce errors to the measurement due to standardizing with
a cooled sensor package. To overcome this potential error, release SP280.2
introduces a feature which will delay the standardize if the head has been off-sheet
for more than a specified amount of time. In this case, the head will forego any
scheduled standardize until such time as a prescribed time on-sheet has been
accomplished. During this time delay, the measurements will be valid provided
there was an initial good standardize.
There are four instance variables located in the scanner01 object associated with
this feature. Two are setup variables, offSheetTime and onSheetTime; while the
other two, stdzRequested and stdzDelayRequired, are status flags used to identify
the current status of any standardize delay. The default condition for offSheetTime
and onSheetTime is a 0. This will turn off the feature. Any non-zero positive value
(time in seconds) in these two variables will activate the feature. The values used
will necessarily be site and installation specific, depending on the temperature
environment surrounding each frame. Experiment to determine the correct off- and
on-sheet delay times.
This feature is primarily beneficial for the Caliper and OptiPak sensors and on Off-
Machine Coaters where standardize should be delayed after machine startup. Other
sensors may also benefit where on and off–sheet temperature differences are
considered large. Unless large temperature differences are present, turn off the
feature if a Caliper or OptiPak sensor is not present in the configuration. However,
if it is on, it will control the standardize of all sensors in the system.
Setup Procedure
1. Activate the inspect utility.
2. Enter the desired off-sheet time in seconds:
scanner01 -> offSheetTime = xxxx (0 = off)
3. Enter the desired on-sheet time in seconds:
scanner01 -> onSheetTime = yyyy
4. Exit the inspect utility by typing: :q
5. Save the changes to the frame community using the gstore utility.


Operation Overview
When the head is moved off-sheet, a timer is started. When the time accumulation
equals that of the offSheetTime value, the system will set the stdzDelayRequired
flag. If a DIRT standardize request then comes from the host, the standardize request
will be so noted in the stdzRequested flag, but the actual standardize procedure
will be delayed until on-sheet has been requested and the head has been over the
sheet for at least onSheetTime seconds. Note that a single point request will start
the on-sheet timer, but that standardize will not occur until the mode changes back
to scan or off-sheet.


Other Host Setup Procedures

The Host computer has several other important parameters that must be entered to
assure proper operation of the measurements system including the following:
• Scanning time, typically takes 15-30 seconds
• Number of profile points, typically takes 100-600
• Standardize interval, typically takes 30-120 minutes
• Product code slopes, offset, compensations, and IR 4-filter flag
• Composite profile filter factor
• Requests for report printing
• Trend graphing of measurement and standardize results
Please refer to the appropriate system manuals for details.


6
Measurement Setup
Measurement setup consists of a set of procedures that involve both the sensor and
the Smart Platform. Specific sensors have additional hardware setup procedures
that are located in the specific sensor manuals. Refer to the Setup Checklists for
the setup procedures sequence for each sensor.
Section............................................................................................... Page
Setup Checklists ............................................................................................ 112
Operation of the Sensor Health Pages ........................................................... 116
Temperature Controller Setup for Basis Weight, Ash, and Caliper Sensors . 118
Setup of Customer Units ............................................................................... 124
Enter Calibration Head Constants ................................................................. 127
Standardize Limits ......................................................................................... 141
Verification .................................................................................................... 155
Air Temperature Compensation for Basis Weight ......................................... 157
Air Profile Compensation for Basis Weight, Gloss, and Caliper .................. 161
Air Profile Compensation for OptiPak .......................................................... 164
Digital Input Invert Adjustment for the Smoothness Sensor ......................... 166
Default Compensations for IR Moisture, Microwave, and Ash Sensors ....... 167
Calibrate Sample - Minimum Time Data Accumulation ............................... 168
101764-003 Measurement Setup 111


Setup Checklists
Newer sensor manuals may address all of these sensor

setup activities in more detail. Always review your sensor
manual for information which may supersede the
contents referred to here.
Basis Weight Sensor Setup
Newer sensor manuals may address all of these sensor setup activities in more detail.
Always review your sensor manuals for information which may supersede the
contents referred to in this chapter.
Table 6-1 Basis Weight Sensor Setup
Procedure Refer To
Align the Sensor Heads page 45
Set up the Temperature/Air Flow page 118
Enter the Head Constants page 127
Set the Standardize Limits page 141
Verify the Sensor Function page 155
Setup for Correct Ream Size page 124
Air Temperature Compensation page 157
Air Profile Compensation page 161
IR Moisture Sensor Setup

Table 6-2 IR Moisture Sensor Setup
Procedure Refer To
Align the Sensor Heads AccuRay 1190 HemiPlus Moisture
Sensor manual, 101766-003
Set up Cooling Unit page 59
Adjust the Air Wipes AccuRay 1190 HemiPlus Moisture
Sensor manual, 101766-003
Setup Default Compensation page 167
112 Measurement Setup 101764-003


OptiPak Sensor Setup

Table 6-3 OptiPak Sensor Setup
Procedure Refer To
Align the Sensor Heads AccuRay 1190 OptiPak Sensor manual,
101766-007
Air Pressure Verification AccuRay 1190 OptiPak Sensor manual,
101766-007
Calibration of the Head Constants
Set the Standardize Limits
Verify the Sensor Function
Set up the Air Profile Compensation
Ash Sensor Setup

Table 6-4 Ash Sensor Setup
Procedure Refer To
Align the Sensor Heads page 45
Set up the Temperature /Air Flow page 118
Verify Source High Voltage Supply For STLXR3, refer to Smart Ash Sensor
Power–up and Adjustment Manual, Part Number 101766-015
For TLXR3, refer to 1190 2–
Component and 3–Component Ash
Sensors Manual, Part Number 101766-
006
Gloss Sensor Setup

Table 6-5 Gloss Sensor Setup
Procedure Refer To
Align the Sensor Heads AccuRay 1190 Gloss Sensor Manual
101766-008
Adjust the Air Wipes
Filter Regulator Assembly
Air Supply Quality Verification
Set up the Air Profile Compensation page 161


Apparent Density Setup

Table 6-6 Apparent Density Setup
Procedure Refer To
Set up for Correct Density Units page 114
Caliper Sensor Setup

Table 6-7 Caliper Sensor Setup
Procedure Refer To
Power Checks
Caliper Filter Regulator Assembly Contacting Caliper Sensor Manual,
101766-005
Caliper Sensor Technical Manual with
FirstSight Technology, 101045-001
Air pressure Verification
Non-Contacting Caliper Sensor
Manual, 101800-001
Align the Sensor Heads
Smart Caliper GT Sensor Manual,
103015-001
Set Up the Temperature Controller page 118
Set Up the Air Profile Compensation page 161
Set Up for Correct Units (Mils/ page 125
Microns)
Sheet Temperature Sensor Setup

Table 6-8 Sheet Temperature Sensor Setup
Procedure Refer To
Align the Sensor Heads Sheet Temperature Sensor Reference
Air Purge Manual, 101766-010
Power Checks
Calibrate and Enter the Head Constants

Set the Standardize Limits
Verify the Sensor Function


Smoothness Sensor Setup

Table 6-9 Smoothness Sensor Setup
Procedure Refer To
Alignment of Sensor Heads
Set Up the Cooling Unit AccuRay 1190 Liquid Cooling Unit
Reference Manual, 101333-003
External Electronics Setup
Nitrogen System Setup
Digital Input Invert Adjustment page 166
Performance Verification
Microwave Sensor Setup

Table 6-10 Microwave Sensor Setup
Procedure Refer To
Alignment of Sensor Heads Microwave Moisture Sensor Manual,
101766-004
Calibrate Temperature Compensation
Verify Sensor Function Microwave Moisture Sensor Manual,
101766-004
Smart Color Sensor Setup

Table 6-11 Smart Color Sensor Setup
Procedure Refer To
Alignment of Sensor Heads Refer to the Smart Color Sensor
Enter the Head Constants Support Manual, 101797-001.
Set Standardize Limits
Verify Sensor Function
IR CoatWeight Sensor Setup

Table 6-12 IR CoatWeight Sensor Setup
Procedure Refer To
Alignment of Sensor Heads Refer to the Smart ReflectionPlus
Enter the Head Constants CoatWeight Sensor Manual, 103029-
001.
Set up Cooling Unit
Set Standardize Limits
Verify Sensor Function


Operation of the Sensor Health Pages

1. Press the F7 key to open the Health Page window from the DESQview window
showing the AVOS ($$) prompt..
The first page to appear after the startup data is the Overview page (see
Figure 6-1). The Overview page shows the Smart Platform status of each sensor,
the Frame Control Panel (FCP) status, and the scanner graphic with numeric
positions. Each sensor in the status display shows a key identifier in brackets.
This is the key stroke which will give access to the sensor specific Health Pages.
Smart Platform Health Overview

Smart Platform Status
[F] [E] [I] [V]
Frame ELECTRONICS IR MOISTURE AIR COLUMN
OK OK OK OK
[C] [B] [A]
CALIPER BASIS WEIGHT ASH
OK OK OK
FCP ABB SMART PLATFORM SHUTTER

Offsht OnSht
*
Manual Comp
*
RevJog FwdJog ShtBrk HstCom
CalSmp ChkSmp BwtISB BwtHTE
Stdz Maint AshISB AshHTE
Sngl Pt % Home Edge Head Pos Far Edge Sht Brk Ovr
10 85.00 29.92 230.23 OFF

EXIT HELP DATA PRTSC PRVPG NXTPG
Figure 6-1 Example of the Health Overview Page

On each page, the TAB key will initially make the cursor visible. Subsequent
pressing of the TAB key will move the cursor to each sub–panel where selections
can be made.


In the setup panel of each subsystem page, the TAB key will initially make the
cursor visible. Subsequent pressing of the TAB key will cycle the cursor
between the various subsections of each page.
Within the interactive subsection areas of each page, the arrow keys move the
cursor according to the following rules:
• Left and right arrows move the cursor horizontally within each setup panel,
highlighting each entry area on that line.
• The up and down arrows move the cursor to other lines within the selected
page.
2. To change numerical data, enter the new value and press RETURN. For other
entries, the space bar will toggle through the selection options. Press RETURN
when a desired selection appears.
3. To select a panel, use the F6 through F9 keys which correspond to SETUP,
STDZ, SMPCK, and CALIB.
The SETUP selection provides one or more panels in sequence which may be
used to enter tuning constants, standardize limits, and other setup parameters
associated with the selected sensor.
The STDZ selection provides pending and current Standardize Reports
sequentially in the lower right–hand corner of the page.
The CALIB selection provides the Calibrate Sample Report in the lower right–
hand corner of the page.
The SMPCK selection provides the Sample Check Report in the lower right–
hand corner of the page.
The PGUP/PRVPG and PGDN/NXTPG keys allow the selection of other sensor
pages which may be available. Not all sensors have multiple pages.
4. To return to the Overview Page, press the ESC key. New subsystem reports
can be selected without going back to the Overview Page.
5. To exit the Health Page Report, press the ESC key while on the Overview Page.
Additional prompts will appear to determine the desire to leave in the
workstation mode. Confirm the desire to exit and do a gstore if data has been
changed.
The F1 HELP key on the Overview Page gives more detailed information on
the Health Report operation.


Temperature Controller Setup

for Basis Weight, Ash, and Caliper Sensors
Temperature control maintains the measurement area environment for critical
internal components and controls the temperature of the external air column (CAP).
Standard operating conditions include mill air temperature environments that vary
between 10°C and 85°C and sheet temperature up to 148°C. The environment for
internal components and the temperature of the external air column are controlled
by the microcontrollers in the AccuRay Smart Processing Center (ASPC). The
software control has an accuracy of ± 2°C and will maintain the set point within a
precision of 0.5°C. Controller set up is done at the Service Workstation using the
Caliper, Ash, and Basis Weight Health Pages. See Figure 6-2 on page 119 for an
example of the Basis Weight Health Page (the Ash Health Page is similar). For
instructions on how to use the health pages, see the section entitled “Operation of
the Sensor Health Pages” on page 116. Do not change the kp, ki, or kd constants
without consulting a specialist.
Temperature controller tuning parameters are determined by the nature of the
thermistor type and the immediate heating environment involved. Use the Caliper,
Ash, and Basis Weight Health Pages (see “Operation of the Sensor Health Pages”
on page 116) to make the appropriate entries.
Temperature target should be between 45° C and

65° C (never above 65° C) or electronics damage may
occur. Set temperature about 10° to 20° cooler than the
temperature four inches from the sheet.


Basis Weight Health Report

Sensor Type: STLK-11 Sensor Command: FROM HEAD Active Alarms: NO

Flag In Use: NO APC: INACTIVE
Measurement INVALID H 4041
HEATER SETUP
Src Det Src Det
Col Col Col Col
10.00 30.00
Maintenance Limit °C 100.0 130.0 Kp
125.0 148.0 0.025 0.015
Power Down Limit °C Ki
0.000 0.000
55.0 55.0 Kd
Setpoint °C 0.500 0.500
0 0 Alpha
Thermister Type 6.00 6.00 20 20
Purge High Limit VDC Delay Sec
1.40 1.40
Purge Low Limit VDC
Src Temp °C 54.91
Det Temp °C 54.99
Deviation from Setpt

B Src - - - Det - - - -
W Src Gap Temp °C 49.20
C
10
Col Temp °C 54.76 o
H
e
Det Gap Temp °C 47.52 m
a Col Temp °C 54.93 p
u °C 0
t t
e e
r r
s Src Htr Duty Cycle%8 -10
Det Htr Duty Cycle%13
0 5 10 15 20

Figure 6-2 Example of Basis Weight Health Page 2 of 2 for Heater Setup


Smart Ash and Smart Basis Weight

Temperature controller setup consists of setting control set points and adjusting the
air flow. The set point for both the source and detector module should be the same
(see Table 6-14 on page 122). The air flow should be adjusted for 4 - 4.5 scfm air
flow for each module.
1. Be sure that the Ash and Basis Weight sensor modules are cold and have been
off–sheet and powered down so that the heads start off cool.
2. Turn Off the air flow to each module. The valves are located on the air manifold
on the back of the basis weight source and detector modules. Valves should be
marked.
3. Set the temperature set point for each module.
Note: This adjustment must be made before the source controller begins
to operate. If additional time is required, move the source set point
to a higher temperature. Be sure not to leave the controller at this
higher temperature.
4. Adjust the source air flow while observing the source heater current at the
Service Workstation. Adjust flow for 2.2 amperes, this should correlate to about
4.0 scfm. The on time duty cycle must be at 100.
5. Repeat Step 4 for the detector module flow and detector heater current.
6. Reset the temperature set points for the desired operating point as directed in
Table 6-14.
Note: A hot process requires higher set points. For basis weight and ash,
the CAP air system will provide both heating and cooling capabilities,
different from previous designs.
7. If ambient conditions are greater than 85°C, then air flow to each module must
be increased. If an air flow of 8.5 scfm is reached at about 3.5 amperes, refer
to Table 6-13 on page 121.


Table 6-13 Flow Versus Current with the Heater Fully On

PTC Heater Character at 30°C Input Air
Amperes scfm
1.4 2.2
1.8 3.7
2.6 5.7
3.6 8.7
3.7 9.8
Flow ≈ Amps * 2.8 -1.8
8. Jog the head package to the coldest location, probably off–sheet, for at least
one hour. Verify that the source and detector heater duty cycle is less than 90%.
See Figure 6-2 on page 119 for detector heater and source heater duty cycles.
9. Locate the head package in the hottest location for one hour. Verify that the
source and detector heater duty cycle is greater than 5%.
10. If Steps 8 or 9 fail, then repeat Steps 4 and 6 to obtain reasonable operation.
Increasing air flow or control set point will increase duty cycle; lowering air
flow or control set point will reduce the duty cycle.
Note: When the sensors are cold, allow 20 minutes before control
begins to operate. One hour is required before the sensors
are stable enough for measurement or before duty cycle
evaluation.
The Basis Weight detector sensor has a longer thermal time

constant. It will take longer for it to come into control.


Temperature Controller Tuning Parameters

Refer to Table 6-14.
* Set to a nominally estimated sheet temperature
** Set to 5° C less than the head heater set point
*** Set to 10° C less than the head heater set point
Table 6-14 Temperature Controller Tuning Parameters
Temperature Set Therm Gain Filter Cont
Controller Point Type Delay (Kp) Ki Kd (alpha) No.
BW source head * 0 20 18.000 0.003 0 0.500 0
(TLK/TLP)
BW detect head * 0 20 15.000 0.002 0 0.500 1
(TLK/TLP)
BW detect head * 1 20 15.000 0.003 0 0.500 1
(TLS)
BW source CAP ** 0 200 18.000 0.003 0 0.500 0
BW detect CAP ** 0 200 18.000 0.003 0 0.500 1
BW source HAW *** 0 20 15.000 0.006 0 0.500 0
BW detect HAW *** 0 20 5.000 0.003 0 0.500 1
BW source head * 0 20 10.000 0.025 0 0.500 0
(STLK-11, STLP-3)
BW detect head * 0 20 30.000 0.015 0 0.500 1
(STLK-11, STLP-3)
Ash source head * 0 0 24.000 0.002 0 0.500 0
(old)
Ash source head * 0 80 10.000 0.025 0 0.500 0
(STLXR)
Ash detect head * 0 80 25.000 0.01 0 0.500 1
(STLXR)
Caliper probe * 1 60 2.0 0.04 0 0.500 0


Using the Optional Temperature Controller Utility

1. At the $$ prompt, Type:
uc_heat n
(where n = 1 for BW head heaters)
6 for Ash head heaters
34 for IR head heaters
35 for Caliper probe
36 for HAW/CAP
39 for BW HAW/CAP heaters
2. When enter menu comes up, select 2 to change heater setup data.
Current Microcontroller number is 0x1
Enter 1 to display heater data
2 to change heater setup data
3 to monitor one controller
4 to change microcontroller number
5 to quit this utility: 1
3. When asked, select the desired controller number. The utility requests inputs
in the following order (xxx indicates the current value):
Enter temperature target scaled by 10 (or <cr> for xxx):
Are further changes needed for this heater controller? (y or n):
(answer n if just want to set target)
Thermister type 0 for 5k, 1 for 100k (<cr> for xxx):
Startup delay in seconds (<cr> for xxx):
Controller gain (K) scaled by 1000 (<cr> for xxx):
Integration constant (Bi) scaled by 1000 (<cr> for xxx):
Derivative constant (Nd) scaled by 1000 (<cr> for xxx):
Noise filter constant (alpha) scaled by 1000 (<cr> for xxx):
4. At the conclusion, the utility will respond with the line:
Enter heater controller number (0 - 3), 4 to send, or 5 to abort:
Either select a new controller on that same ECS board, send the new data to the
ECS board, or abort the process.
If all the microcontroller within the ECS board have been changed during the
session, the data will automatically be sent down without requesting it
manually.


Setup of Customer Units

Ream Size
The ream size conversion factor converts the internal computation of basis weight
from grams per square meter (gsm) to customer units of pounds per ream. If
customer units are to be gsm, the conversion factor is 1.0. Consult the Calibration
Report for the correct value and enter it into the software variable name reamSize.
Ream size is, by default, controlled from the Smart Platform Basis Weight Health
Page. It is possible to have the Host Computer determine the Ream Size by changing
a flag called hostDefaultReamSize in the betaSensor01 object using the inspect
utility. If this flag is set to a “1”, the ream size will be determined by what the host
sends down at a grade change or a PMMRLD command. If it is a “0”, the default
condition, then the Health Page controls it exclusively. It is still possible to
temporarily change it from the Health Page as shown below, however, care must be
taken to return it to its original value when done. This feature is only available on
Software Release 280.2 or later, and it will only function if the host has been
modified to use it.
Changing Ream Size
1. Access the Basis Weight Health Report from the Service Workstation. Refer
to Figure 6-2 on page 119.
2. Press the TAB key to cycle the cursor to the setup panel. Use the arrow keys
to position the cursor on the Ream Size entry.
3. Change the ream size by changing the Ream Size value on the setup panel of
the Basis Weight Health Report.
4. Changes to ream size are immediately displayed in the Measurement Results
panel of the Basis Weight Health Report.


Apparent Density
Apparent density is a computation of basis weight divided by caliper. It is presented
on the Host computer display in LMR units. This is weight per Mil–Ream. The
default units in the software are metric, or grams per micron–square meter. This is
controlled by an instance variable called customerUnitsConversionFactor in the
pmmApDens01 object. For metric systems, the value is 1.0. For English systems,
the value will depend upon the ream size and is governed by the following algorithm:
customerUnitsConversionFactor = 0.0052 * reamSize
Using the above algorithm, the computed value for
customerUnitsConversionFactor should be entered into the system using the
inspect utility and typing the following at the I>:
()[pmmAppDensity01 customerUnitsConversionFactor:x.x]
and then stored on the diskette to the PMM community by using the gstore utility.
To make the change effective without restarting the system, simply initiate a small
edge change. The recalculation of the customerUnitsConversionFactor is
included in the edge change adjustment activity.
Changing Caliper Output Units
To change the output units for the Caliper sensor, access the Miscellaneous Setup
panel on the Caliper Health Report. Refer to Figure 6-3 on page 126.
1. Press the F6 key to bring up the desired setup page.
2. Place the cursor on the units designation and press the SPACE BAR at the
terminal to toggle through the selections of units.
3. Press the RETURN key when the desired units appear.


Caliper Health Report

ABB Process Automation FWS170.009 01-31-96 11:42:59
SP Release: 280.2 Page 1 of 2
Head Command: OFFSHEET System Alarms: NO
Sensor Type: GT Sensor Command: FROM HEAD Active Alarms: NO

APC: INACTIVE
Measurement: INVALID H 4000
MISCELLANEOUS SETUP
Customer Units Conversion Factor MICRONS 1.00000
Zero Filter Factor, Up 0.80
Zero Filter Factor, Down 0.30
Defect Detection Threshold Level VDC 1.0
Internal Check Sample Offset PPT 200
NDS for Check Sample # 5
Caliper Microns 4466.732

Caliper CU 4466.732
Press. Tp/BtmMB 0.0
Stdz Pending 01/30 16:59:58
Caliper Signal VDC 8.5747
Pressure Top VDC 6.4472 Alarm PASSED
C Sensor Max VDC 8.5741
a Pressure Btm VDC 6.4969 C
Defect Count # 0 Sen Max Noise 0.0000
l o Sensor Zero VDC 1.9372
m Sensor Zero Raw VDC 1.9372
S p Zero Gap MICRONS 154.7
e u Press Zero Top VDC 6.4461
n t Press. Zero Btm VDC 6.4965
s e Pressure Top MB 29.9
o Top Head Active NO r Pressure Btm MB 27.4
r Bottom Head Active NO
(Expanded report on page 2)

Figure 6-3 Example of the Caliper Health Report
Ash Units Setup

Ash units are determined by the Host computer. Refer to the Host computer
documentation for setup of percent basis weight, percent bone dry weight, and ash
weight.


Enter Calibration Head Constants

Calibration head constants have to be entered into the Smart Platform software.
The values for these constants can be found on reports for the Basis Weight (includes
Air Column), and Ash sensors or tags for the IR Moisture and Caliper sensors. For
the OptiPak and Gloss sensor, values are entered through an interactive genrpt
program that allow the software to calibrate the constants it needs on line.
Basis Weight Sensor
The Basis Weight sensor head constants are K0, K1, K2, K3, WCC, and AM. These
constants may be different for every sensor. They may need to be changed if certain
components in the sensor geometry are repaired or replaced. Change sensor
constants using the Basis Weight Health Page, Figure 6-4 on page 128. See
“Operation of the Sensor Health Pages” on page 116, for instructions for using the
Health Pages.
The Basis Weight sensor calibration constants consist of one or two sets of
constants. Table 6-15 lists the head constants for the Basis Weight sensor, which
are different for each sensor manufactured.
Table 6-16 on page 128 lists the optional constants for the Air Temperature
Compensation (ATC) which are determined by the sensor model number.
Table 6-15 Basis Weight Calibration Constants
Value – betaSensor01
Head Constant (Enter values from the Calibration Report)
K0
K1
K2
K3
WCC
(Smart Basis
Weight only)
AM
(Smart Basis
Weight only)



INTEGRATION LOAD SP Release: 280.2 Page 1 of 2
DEVEL-1 Frame Ctrl From: END COLUMN Head Safety Intr: RESET
REEL Command: OFFSHEET System Alarms: NO
Sensor Type: STLK-11 Sensor Command: FROM HEAD Active Alarms: NO
Electrometer Test: OFF Flag In Use: NO APC: INACTIVE
Measurement: Valid
CALIBRATION TUNING CONSTANTS

CONSTANTS NOMINAL Range
K0 53.51300 Gap WCC GRAMS 0.000000 AIS VDC 4.8000 2.5500
K1 -5.14000 Air Mass GSM/MM 1.700000 AIZ VDC 0.0600
K2 -0.430000 MISCELLANEOUS SETUP Dirt GSM 18.750 21.250
K3 0.133000 SmpChk Avg TIme SEC 20 NOISE Z 0.0010
Stdz FS Avg Time SEC 50 NOISE F 0.0050
NAUTO (BW only) 0 NOISE T 0.2000
Ream Size 0.0
Basis Wt GSM -0.070
Air Col Comp GSM X.XXXX Basis Wt CU -0.070
Electrometer VDC -0.0007 Stdz Pending 01/3106:56:30

Alarm Grid DOES NOT EXIST Alarm PASSED
B Shutter State:
W C AIZ VDC 0.0002
Sensor I/O CLOSED AIS VDC 4.9533
Frame I/O CLOSED o
S m NOISE Z 0.0000
e p NOISE F 0.0000
n u DIRT GSM 0.000
s t TCLEAN DAYS 0
o e Src Temp °C 54.98
r Electrometer Test OFF r Det Temp °C 54.96
Engage Int Ck Smpl NO
Open The Shutter FALSE AIS HI/LO XX.XXXX/XX.XXXX

Figure 6-4 Basis Weight Sensor Health Report Showing Calibration Constants
Table 6-16 Basis Weight Sensor ATC Calibration Constants
Basis Weight Sensor Model
ATC Constant TLK-5 TLK-8 TLK-9 TLP-1
KT0 0.0 0.09765 0.1758 0.0
KT1 0.5859 0.09375 0.2148 0.1953
KT2 -0.3477 0.2813 0.0 0.1953
KT3 0.0 0.0 0.0 0.0
dBWdT -0.1 -0.1 -0.1 -0.1
Enter the calibration head constants into the Smart Platform software through the
Basis Weight Health report.


Air Column Measurement

(Smart Basis Weight Sensor Only)
Air column measurement constants are changed using the Air Column Sensor
Health Report in a manner similar to the way Basis Weight sensor constants are
changed (see Figure 6-4 on page 128 and Figure 6-5). There are five air column
measurement sensor constants, KZ0, KZ1, KZ2, KZ3, and gap offset (see Table 6-
17 on page 130). These constants are shown as K0, K1, K2, and K3 on the screen.
Air Column Health Report

Sensor Command: FROM HEAD Active Alarms: NO
Measurement: VALID
DELTA COLUMN CALIBR CONSTANTS STANDARDIZE CONSTANTS

Maint Limit MM 1.000 K0 83.424995 Nominal Range
Invalid Limit MM 3.000 K1 2.995000 Column MM 7.000 1.500
K2 0.013090 Volts VDC 1.100 1.000
K3 68.169998
Offset -2.171435
Delta Column MM 0.046
Column VDC 1.0719 Stdz Pending 01/31 06:56:30

C
o Alarm PASSED
l C Stdz Column MM 6.739
o Sigma Column VDC 0.000
S m Stdz Volts VDC 1.045
e p
n u
s t
o e
r r

Figure 6-5 Air Column Measurement Health Report


Table 6-17 Air Column Measurement Constants

Head Constant Value
(Enter values from the Calibration Report)
KZ0
KZ1
KZ2
KZ3
gap offset


IR Moisture Sensor
Calibration head constants are found on the calibration tags on each IR sensor. To
enter those values into the Smart Platform software, follow the instructions in
“Operation of the Sensor Health Pages” on page 116. The head constants are listed
in Table 6-18 on page 132.
IR Moisture Health Report

DEVEL-1 Frame Ctrl From: HOST Safety Intr: RESET
REEL Head Command: SCAN System Alarms: NO
Sensor Type: REFL PLUS Sensor Command: FROM HEAD Active Alarms: NO
Sensor Mode: PLUS Chiller 1: FLOWING
Measurement: VALID Chiller 2: FLOWING
STDZ & SAMPLE CHECK CONSTANTS

A 3.692000 A1 -0.000095 A2 0.0000076 A3 0.0000076
B 7.819000 B1 0.013400 B2 -0.003900 B3 -0.003900
C 0.632000 C1 0.370300 C2 1.085300 C3 1.085300
DELTA1 -0.546000 D1 0.003870 D2 0.000000
DELTA2 -0.573000 CW1 -0.025000 CW2 0.36190
KF1 995 SDELTA 1128
KF2 891 KF 1024
WTBP 100.0 WTBP2 250.0
Moisture PCT 5.62

Ash Comp% 0.000 Ratio IR1 0.76
Ratio IR2 0.12
Lamp Curr VDC 1.055 Sample Check 01/31 06:56:35
Lamp Volts VDC 12.589
I Hd Revolutions RPS 60.0 Alarm PASSED
R C IR1 IR2
o AAIR VDC 6.3564 5.8248
S m RAIR VDC 6.1821 6.2965
e p SIGMIR 0.000000 0.000000
n u KC 1.0282 0.9251
s t IRGAIN 4
o e
r r HI KC xx.xxxx xx.xxxx
LO KC xx.xxxx xx.xxxx
Lamp DO OFF

Figure 6-6 IR Moisture Health Report Showing Calibration Constants


Table 6-18 Head Constants

Nameplate Name Value to Enter
A1
A2
CW
B1
B2
WTBP
SDELTA or DELTA
A
B
C
DELTA1
DELTA2
KF1 of KF
KF2
A1
B1
C1
D1
CW1
A2
B2
C2
D2
CW2
A3
B3
C3
WTBP1
WTBP2


Ash Sensor
The Ash sensor uses seven unique head constants for a flag-in operation and another
unique seven constants for a flag-out operation. If the sensor is a Smart Ash, then
there are an additional two head constants required. These are listed in Table 6-19.
The 14 values for flag-in/flag-out operation are found in the Ash Calibration Report.
The two additional constants for Smart Ash operation are found in the calibration
report for the Smart Basis Weight, under the Air Column data.
Head constants from the calibration report can be entered into the system using the
Ash Sensor Health page, Figure 6-7 on page 134. The second setup panel is selected
by pressing the F6 function key. See “Operation of the Sensor Health Pages” on
page 116, for instructions on using the Health Pages. Table 6-19 lists the head
constants for the Ash sensor.
Table 6-19 Ash Sensor Head Constants
Head Constant Flag-In Flag-Out
BW Corr Factor (A2)
Corr Offset (B2)
Mo Corr Factor (C2)
K0
K1
K2
K3
Gap WCC (Smart Ash Only)
Air Mass (Smart Ash Only)


Ash Health Report

ABB Process Automation 05-26-92 11:00:35
Workstation Mode Test SP Release: SP210.5 Page 1 of 2
1 Frame Ctrl From: END COLUMN Safety Intr: RESET
1 Head Command: OFFSHEET System Alarms: NEW
Sensor Type: S3-C Sensor Command: FROM HEAD Active Alarms: NO
Flag In Use: NO APC: ACTIVE
Measurement INVALID H 4846
CALIBRATION CONSTANTS FULL SCALE STANDARDIZE LIMITS

Flag In Flag Out Flag In Flag Out
BW Corr Factor (A2) 28.79000 28.18000 Nominal 5.1000 6.0000
Corr Offset (B2) -33.03000 -33.14000 Range 1.0000 1.0000
Mo Corr Factor (C2) 0.011330 0.10940 Noise Range 0.5000 0.5000
K0 49.56200 53.51300
K1 -5.02000 -5.14000
K2 -0.350000 -0.430000
K3 0.138000 0.133000
Basis Wt Comp GSM 150.00 Ash Wt GSM 0.000

Moisture Comp % 7.00
Air Col Comp GSM X.XXX Stdz Current MM/DD HH:MM:SS
Electrometer VDC 0.0229 Alarm PASSED

A Hi Volt Mon VDC 5.4174 AIZ VDC 0.0000
s Anode I Mon VDC 0.6152 C NOISE Z VDC 0.0000
h Shutter State: o
Sensor DI CLOSED m Flag Flag
S Frame DI CLOSED p In Out
e u
n t AIS VDC 5.1000 6.0000
s e Noise F VDC 0.0000 0.0000
o Electrometer Test DO OFF r Src Tmp °C 0.00 0.00
r Flag DO OUT Det Tmp °C 0.00 0.00
Open The Shutter DO FALSE HV Mon VDC 0.0000 0.0000

TUNING CONSTANTS MISCELLANEOUS SETUP
Ignition Factor 1.000 NAUTO 0

Gap WCC GRAMS 0.000000
Air Mass GSM/MM 1.500000
Figure 6-7 Ash Sensor Health Report


Sheet Temperature Sensor

Use the Sheet Temperature Health Pages to change the calibration constants (see
“Operation of the Sensor Health Pages” on page 116.) Figure 6-8 shows an example
of the Sheet Temperature Health Report.
For instructions on calibrating the Sheet Temperature sensor, see the AccuRay 1190
Sheet Temperature Sensor Reference Manual, 101766-010.
Sheet Temperature Health Report

Frame Ctrl From: HOST Safety Intr: RESET
Head Command: SCAN System Alarms: NO
Sensor Command:FROM HEAD Active Alarms:NO
CALIBRATION CONSTANTS STANDARDIZE LIMITS
Fine Tune Slope 0.0000 Lo Temperature °C 0.00

Fine Tune Offset °C 0.0000 Hi Temperature °C 0.00
Center Temperature °C 0.00
Sheet Temp °C 0.00
Sheet Temp VDC 0.0000 Stdz Current 1/02 3:04:00

T Alarm PASSED
M C Sheet Temp °C 0.00
P o Actual Gain 0.0000
m
S p
e u
n t
s e
o r
r

Figure 6-8 Sheet Temperature Sensor Health Report Showing

Calibration Constants


Gloss Sensor
Table 6-20 identifies the variable names of the two head constants for the Gloss
sensor. Enter the values you read from the sensor head nameplate into the specified
instance variable column and store them in the frame community using the gstore
utility.
Table 6-20 Head Constants for the Gloss Sensor
NamePlate Name Instance Variable Name Value
GL1HC1 headConstant1
GL2HC2 headConstant2
1. At the $$ prompt type genrpt.

The current calibration head constants, giving variable name and current value,
will be displayed on the console. The bottom portion will be an interactive
question about changing, redisplaying, or recalculating the current values. See
Figure 6-9.
GENERAL SENSOR REPORT TUNING UTILITY; rev date 8 Sep. 1989.

Enter the name of the sensor you wish to view.
TopGlossSensor01
Do you wish to view Standardize variables or Calibration constants? (s or c)
c
GLOSS SENSOR CALIBRATION CONSTANTS TUNING UTILITY; rev. date 27 Mar., 1990.
Current Calibration Constants
Variable Name Current Value

1: headConstant1 26.00000
2: headConstant2 0.000000
Enter 1 to change head constants

2 to re–display head constants
3 to calculate new head constants
q to exit
Do you wish to view another sensors report? (y or n) n
Figure 6-9 Example of Gloss Sensor Calibration Report

2. If a current value is to be changed, enter a 1 and continue to the next step. If
you wish to redisplay the constants, enter a 2 and observe the screen refresh.
If you wish to calculate new constants, enter a 3 and follow the interactive
instructions. If no changes are to be made, answer q and skip to Step 6.
3. If 1 is selected, the console will then ask which variable is to be changed. Enter
the variable number. If 3 is selected, go to the Gloss Sensor Head Constant
Tuning Procedure below..


4. The console will then confirm the variable name and wait for the new value to
be entered.
5. The console will ask again if a variable is to be changed. If yes, answer y and
go back to Step 3. If no, answer n and continue.
6. The console will give instructions regarding the selection of another report if
desired. If no, answer n and the utility will exit to the AVOS shell ($$). If yes,
answer y and the utility will restart as if genrpt had just been entered.
Gloss Sensor Head Constant Tuning
The gloss head constants are adjusted so that the sensor will correlate to the
laboratory measurements. Since the instruments used in the lab will read slightly
different from one to another, the head constants determined in Columbus are
attached to the sensor, but are marked as approximate numbers.
The following interactive procedure is to be used to fine tune the sensor response
to the customer’s lab. It uses two lab sample readings which are entered by the
user, and the results of the sample check readings on the same two samples. The
recalibration routine is selected interactively using genrpt. After running the
routine, and there are no errors, the newly computed head constants are stored in
memory. The user must save the new values to RAM disk in the frame community
by using the gstore utility.
Note: This procedure involves a series of interactive steps including work

at the console and performing sample checks. Before starting, read
through the entire procedure making sure that all resources and time
are available to complete the procedure without interruption.
1. Ensure that the laboratory instrument is calibrated with the calibration standards
that come with it.
2. Read the Gloss sensor’s check samples on the laboratory device, noting the
proper measurement area and direction of measurement. Take several readings
and calculate the average.
3. Allow the Gloss sensor to thermally stabilize for at least two hours. Clean the
windows and standardize.
4. Place the Gloss sensor in sample check mode 1 from the Host computer.
5. Activate genrpt for the Gloss sensor and select recalibration by entering a 3.
6. Enter the average Lab 1 sample value at the prompt.
7. Run a sample check on the same sample used for Lab 1.
8. Enter the average Lab 2 sample value at the prompt.
9. Run a sample check on the same sample used for Lab 2.
10. The new head constant values will be reported. If there are no errors, the user
will be instructed to write the values to diskette using the gstore utility.


11. Exit the sample check mode when completed.

Error Conditions
• The absolute value of the difference between the two lab values
(Lab 2 – Lab 1) is less than or equal to 15.
• Calculated head constant GL1HC1 is less than 5 or greater than 50.
• Calculated head constant GL1HC2 is less than -15 or greater than 15.


Caliper Sensor
Use the Caliper Health Pages to change the calibration constants (see “Operation
of the Sensor Health Pages” on page 116). Figure 6-10 shows an example of the
Caliper Health Report. Caliper calibration constants for your caliper sensor may
be different. See the appropriate caliper sensor manual and your calibration report.

ABB Process Automation FWS170.009 01-31-96 11:42:59
Head Command: OFFSHEET System Alarms: NO

APC: INACTIVE
SENSOR FLAGS SENSOR CALIBRATION

Check Pressure Yes KK1 60.074299
KK2 -0.626889
KK3 8.780809
SENSOR CORRELATION KK4 -1.530780
KK5 0.115090
Dynamic Offset (KDYN) Microns 0.000 SZCAL 0.000000
Global Offset (KOFF) Microns 0.000
Global Slope (KSLOPE) Microns 1.000
Caliper Microns 4466.732

Caliper CU 4466.732
Press. Tp/BtmMB 0.0
Stdz Pending 01/30 16:59:58
Caliper Signal VDC 8.5747
Pressure Top VDC 6.4472 Alarm PASSED
C Sensor Max VDC 8.5741
a Pressure Btm VDC 6.4969 C
Defect Count # 0 Sen Max Noise 0.0000
l o Sensor Zero VDC 1.9372
m Sensor Zero Raw VDC 1.9372
S p Zero Gap MICRONS 154.7
e u Press Zero Top VDC 6.4461
n t Press. Zero Btm VDC 6.4965
s e Pressure Top MB 29.9
o Top Head Active NO r Pressure Btm MB 27.4
r Bottom Head Active NO
(Expanded report on page 2)

Figure 6-10 Caliper Health Report Showing Calibration Constants


Microwave Moisture Sensor

The Calibration Head Constants are found in the Sensor Calibration Report supplied
with the sensor. The entries are summarized in Table 6-21 given below. Enter them
into the system using the Health Reporting System.
Table 6-21 Microwave Moisture Calibration Constants
Head Constant Value
Wt Slope Factor
Target Moisture
Sensor Slope
Target Voltage
Target Weight
Temp Corr Coeff
Target Temp
Moisture Breakpoint
Temp Correction Factor
Temp Correction Exponent


Standardize Limits
Procedure for Changing Standardize Limits
Refer to “Operation of the Sensor Health Pages” on page 116 for instructions on
how to enter data. Standardize limits are entered via the setup panel on each sensor
report.
General Information
There are a number of options and scenarios available which control how the
standardize feature is to be operated. These are:
• Time interval between standardizes
• The selection of CLEAN or DIRTY standardize modes
• Standardize delay after long off-sheet periods
• Reporting of "internal" check sample during standardize
Time Interval Between Standardizes
The time interval between standardizes is generally controlled by the host computer,
except for AccuRay Direct systems. A minimum time interval should be 30
minutes. On AccuRay Direct systems, the interval is controlled by an instance
variable called stdzPeriod, located in each of the sensor objects present in the
system. If any of the sensors have a non-zero value in this variable, that value will
be used to establish the standardize interval. For AccuRay Direct systems
interfacing with a foreign DCS (not Smart CD to an 1180M), only one sensor needs
to have an interval defined since one serves all. On AccuRay Direct systems, the
default time within each sensor is set to 60 minutes. For AccuRay Direct connected
to an 1180M via the Smart CD interface, the value for the stdzPeriod in each sensor
should be set to zero if the interval being scheduled by the host is greater than 60
minutes. If it is less, then no change is required since the most frequent interval
prevails.


The Selection of CLEAN or DIRTY Standardize Modes

CLEAN and DIRTY standardizes are selectable from the host computer (1190 and
1180M) and can be either manually requested or defined at the time of automatic
standardizes. Of all the sensors available in the system, only Basis Weight, GT
Caliper, and OptiPak (FOB) have any sensitivity to what mode of standardize has
been selected. It is possible to have one of these sensors responding to a DIRTY
standardize request while the others are held to doing only CLEAN standardizes.
As an example, in a system with both Basis Weight and GT Caliper, it may be
desirable to have the Basis Weight sensor only doing CLEAN standardizes while
the GT Caliper must be doing DIRTY standardizes due to the environmental aspects
of the paper machine. In this case, the host would be set up to request DIRTY
standardizes while the Basis Weight sensor on the Smart Platform is set up to do a
CLEAN standardize every time a DIRTY one is requested. In all cases after a system
reset, regardless of how the various CLEAN/DIRTY flags are set, the system will
force a CLEAN standardize on all sensors which require one. The CLEAN request
will continue until all of those sensors have passed their initial standardize.
Figure 6-11 on page 143 describes the standardize CLEAN/DIRTY mode selection
that takes place when a standardize is requested from either the Host, the Health
Pages (HP), or the Frame Control Panel (FCP). To summarize the three situations,
whenever DIRT standardizes occur and are accepted by the sensors; the OptiPak
sensor can be set up to basically ignore standardize requests, the Basis Weight sensor
will take into account the effect on beam absorption when dust accumulates on the
window, and the GT Caliper sensor will filter the sensor zero (SZERO) results for
GT Caliper to adjust for the effects caused by dust on the probes.


Standardize
request from
FCP
Standardize
request from
HOST/HP
Set Standardize Mode to (clean/dirty)
localStdzMode
(fhi01)
All other FOB Basis Weight GT Caliper

Sensors Sensor Sensors Sensors
CLEAN NO CLEAN YES CLEAN YES

Standardize Request Standardize Request Standardize Request
? ? ?
YES NO NO
Is there
a valid current
NO standardize?
YES Is there NO Is there NO

a valid CLEAN a valid CLEAN
standardize? standardize?
YES YES
Check
defaultStdz Type
=1
=0 =1 =1
check Check
defaulStdzType defaultStdzType
=0 =0
Do Do Do Do Do
Do Do Standardize DIRTY CLEAN DIRTY CLEAN
Standardize Standardize but do not Standardize Standardize Standardize Standardize
update results
Figure 6-11 Standardize Mode Selection


Standardize initiated from the Frame Control Panel (FCP) is either CLEAN or
DIRTY depending on the state of the instance variable localStdzMode in the object
fhi01. The default setting for this variable is DIRTY. This can be changed to be
CLEAN by changing the value from a "0" to a "1" (if this change is to be retained
after a system reset, the "fhi" graph needs to be saved with the "gstore" utility). A
reset is NOT needed to make the change active.
In any CLEAN standardize request, an automatic internal check sample for those
sensors so equipped, is executed.
Note: Three sensor categories require a "good" CLEAN standardize before

they can be made operational after a restart. These are the OptiPak
(FOB), Caliper sensor, and ALL Basis Weight sensors. After a
restart, and regardless of which kind of standardize is being
requested from the host, Frame Control Panel, or Health Pages, a
CLEAN standardize will be scheduled for these sensors until the
initial standardize is passed. The individual sensor manuals should
be consulted to see the effect of a CLEAN or DIRTY standardize
selection.
Standardize Delay After Long Off-Sheet Periods

There is a "delayed standardize feature" which allows the system to delay a DIRTY
standardize request until the head has scanned for a specified amount of time, after
the head has been off-sheet for a specified amount of time. This feature is desired
where a lot of dust is present in the air and this dust settles on the GT Caliper probes
while off-sheet for an extended time. In that case, the head is desired to scan (to
rub the dust off the probes) before doing a standardize. This delayed standardize
feature is also desirable for all the other sensors in that it assures a correct standardize
after the sensors have been reconditioned to the sheet after long idle periods. Not
allowing the sensors to recondition before standardizing can cause measurement
inaccuracies if the head has been off-sheet long enough to cool. During this time
delay, the measurements will be valid provided there was an initial good standardize.
There are four instance variables associated with this feature. Two are setup
variables accessible on the Frame Health Page, offSheetTime and onSheetTime,
while the other two, stdzRequested and stdzDelayRequired, both located in the
scanner01 object, are status flags used to identify the current status of any
standardize delay. The stdzDelayRequired will indicate a 1 if the off-sheet position
has been active for more than the offSheetTime. The stdzRequested instance
variable will indicate if a new request from the host or Health Pages has been
received after the onSheetTime has expired. A value of 0, the current default value
for offSheetTime and onSheetTime, will turn off the feature. The recommended
starting value for the off-sheet timer should be 10 minutes (600 seconds), and for
the on-sheet timer, 6 minutes (360 seconds). Experiment to determine the most
appropriate off and on sheet delay times for each site. This feature is bypassed
when a local standardize is requested from the FCP or if a CLEAN standardize has
been requested from the host or Health Pages.


Reporting of "Internal" Check Sample During Standardize

Several sensors have an internal check sample which is monitored at a CLEAN
standardize request. The internal check sample can be also monitored at selected
DIRTY standardize intervals. The sensors involved are Smart Basis Weight, Smart
Ash, GT Caliper, Color, and IR Coat Weight. There is a instance variable called
NAUTO for each of these sensors. If it is set to 0, no internal check sample will
take place during a DIRTY standardize request. If it is a positive number, then the
number will define the standardize interval between internal check samples done
at DIRTY standardizes. If the number is set to a negative value, then the internal
check sample will place it at the beginning and again at the end of the standardize
sequence.
Health Page Standardize Reports
The standardize report available on the health report has two presentations:
• Pending
• Current
The Pending Report is the last standardize results, either passed or failed, that was
executed. The Current Report is the last passed standardize and is the one the sensor
would be currently using while scanning or in single point. If the Pending
Standardize Report shows failure, the sensor will still be able to show a
measurement on the Health Report, however, the data to the host will be marked
invalid. Selection of the Pending/Current Report is done using the function key F7.
Changing the Standardize Mode of the FCP Standardize
Request
The default standardize mode requested from the FCP is DIRTY. This can be
changed to be CLEAN by changing and saving the mode flag in the FCP data base.
A reset is NOT needed to make the mode flag change active. Note that regardless
of the setting of the mode flag, a CLEAN standardize will always be performed
after a reset.
To change the mode flag, proceed as follows:
2. Change the mode flag by typing:
I> fhi01->localStdzMode=x
where x= 0 for DIRTY
1 for CLEAN
3. Exit the inspect utility by typing: :q
4. Save the change to the frame community using the gstore utility.


Controlling the Type of Standardize for a Specific Sensor

With Software Release 280.1, the system now has the ability of specifying for each
sensor, what type of standardize is to be performed when a DIRT standardize is
requested from the Host. Most sensors do not perform differently for either a
CLEAN or DIRT standardize, but for those that do, it may be desirable at times to
always have a CLEAN standardize even when a DIRT standardize is requested.
The sensors in question which can sense the difference are the weight and caliper
sensors. Another sensor which now joins this group, is the OptiPak sensor. With
this feature turned on for the OptiPak, the sensor will ignore collecting new
standardize data at a DIRT standardize request. The only time the OptiPak sensor
will actually establish new standardize data is when a CLEAN one is selected.
The instance variable defaultStdzType, located in each sensor object, determines
what type of standardize the sensor will perform whenever a DIRT standardize has
been requested by either the host or the workstation. The selection code used to
determine whether it is a CLEAN or DIRT standardize, is “1” for CLEAN and “0”
for DIRT. Therefore, if the defaultStdzType is set to a “1”, the sensor will do a
CLEAN standardize as requested, except of course the OptiPak sensor which will
not standardize at all. CLEAN standardizes are always responded to by the sensors
as requested. the default value of the defaultStdzType for all sensors except for
OptiPak is a “0”. The value for OptiPak is defaulted to a “1”.
It should be noted that no capability in the standardize process has been lost. What
this means is more flexibility as to what type of standardize is done when a DIRT
standardize has been requested.


Smart Basis Weight Sensors

Internal check sample may be automatically initiated at a dirty standardize. It will
be forced at each clean standardize. The variable NAUTO, available through the
inspect utility or the Basis Weight Health Report, determines the frequency of
internal check sample relative to dirty standardize. If set to zero, there will be no
automatic internal check sample. If set to an integer (n) greater than 0, then an
automatic internal check sample will be run every (n) dirty standardize.

DEVEL-1 Frame Ctrl From: END COLUMN Head Safety Intr: RESET
REEL Command: OFFSHEET System Alarms:NO
Sensor Type: STLK-11 Sensor Command: FROM HEAD Active Alarms:NO
Electrometer Test: OFF Flag In Use: NO APC: INACTIVE
Measurement: Valid
CALIBRATION TUNING CONSTANTS

CONSTANTS NOMINAL Range
K0 53.51300 Gap WCCGRAMS0.000000 AIS VDC 4.8000 2.5500
K1 -5.14000 Air MassGSM/MM1.700000 AIZ VDC 0.0600
K2 -0.430000 MISCELLANEOUS SETUP Dirt GSM 18.750 21.250
K3 0.133000 SmpChk Avg TIme SEC 20 NOISE Z 0.0010
Stdz FS Avg Time SEC 50 NOISE F 0.0050
NAUTO (BW only) 0 NOISE T 0.2000
Ream Size 0.0
Basis Wt GSM -0.070

Air Col CompGSMX.XXXX Basis Wt CU -0.070
Electrometer VDC -0.0007 Stdz Pending 01/3106:56:30

Alarm Grid DOES NOT EXIST Alarm PASSED
B Shutter State:
W C AIZ VDC 0.0002
Sensor I/O CLOSED AIS VDC 4.9533
Frame I/O CLOSED o
S m NOISE Z 0.0000
e p NOISE F 0.0000
n u DIRT GSM 0.000
s t TCLEAN DAYS 0
o e Src Temp °C 54.98
r Electrometer Test OFF r Det Temp °C 54.96
Engage Int Ck Smpl NO
Open The Shutter FALSE AIS HI/LO XX.XXXX/XX.XXXX

Figure 6-12 Basis Weight Health Report Showing Standardize Limits


Caliper Sensor
The Caliper sensor is unique in that only the nominal values may be set by the user.
Ranges, both for failure and maintenance, are calculated internally. The failure
range is calculated every time the nominals are changed. The maintenance range
is calculated only when a clean standardize has been selected.

DEVEL-1 Frame Ctrl From: WORKSTATION Safety Intr: RESET
REEL Head Command: OFFSHEET System Alarms: NEW

APC: INACTIVE
STANDARDIZE
Stdz Results 01/30 16:59:58
Status PASSED
(a) (b)
Current Nominal Failure Last Clean Maint
Variable Name Value Value Range Stdz Value Range
Sensor Max VDC 8.5741 8.5000 1.5000 8.500 0.5000
Sen Max Noise 0.0000 0.0010 0.0020 0.0010 0.0010
Sensor Zero VDC 1.9372 1.9500 1.5000
Sensor Zero Raw VDC 1.9372 1.9500 0.0001
Press. Zero Top VDC 6.4461 6.5600 0.5000
Press. Zero Btm VDC 6.4965 6.5600 0.5000
Pressure Top MB 29.9307 30.0000 15.0000 0.0000 5.0000
Pressure Bottom MB 27.4490 30.0000 15.0000 0.0000 5.0000
Notes: a) “Failure Range” is relative to “Nominal Value”.
b) “Maint Range” is relative to “Last Clean Stdz Value”.

Figure 6-13 Caliper Sensor Health Report Showing Standardize Limits


Acceptable Range for Standardize Limits

Refer to the following tables for the acceptable range of standardize limits for each
of the sensors. See Table 6-22, Table 6-23, Table 6-24, Table 6-25, and Table 6-27.
Table 6-22 Range for Basis Weight Sensor Standardize Limits
Host Report Acceptable
Name Variable Name Function Values
AIZ AIZ Nominal Expected voltage with shutter 0.0 VDC
closed
AIZ Range Plus and minus limits for 0.1 VDC

zeroScaleNominal
SIGMAZ Noise Z Standard deviation of the <0.00001 VDC 2
source closed signal
AIS AIS Nominal Expected voltage output of the 3.0-9.0 VDC
electrometer with nothing in
the gap
AIS Range Plus and minus limits for 0.5 VDC

fullScaleNominal
SIGMAB Noise F Standard deviation of the <0.4 VDC2
electrometer output signal
with nothing in the gap.
DIRT DIRT Nominal One half of the allowed dirt TLK/STLK - 18.5 GSM ± 21.25
accumulation permitted for TLP/STLP - 4.5 GSM ± 5.5
the sensor in gsm TLS - 45 GSM ± 5 5
DIRT Range Equal to the dirtNominal entry
Note: You have to observe source decay, which will reduce the AIS value
by 3.4% per month for STLP and 0.7% per month for STLK sensors.


IR Moisture Sensor
Table 6-23 Range for IR Sensor Standardize Limits
Host Computer Variable Name
Reporting Name In IR Health
Report Description Acceptable Range
AAIR AAIR Standardize air gap reading 6.5 VDC ± 2.5
for the absorption signal on
transmission–type sensors.
RAIR RAIR Standardize air gap reading 6.5 VDC ± 2.5
for the reference signal on
transmission–type sensors.
AFLAG AFLAG Standardize flag reading for 5.7 ± 0.7
the absorption signal on
reflection–type sensors.
RFLAG RFLAG Standardize flag reading for 5.7 ± 0.7 VDC
the reference signal on
reflection–type sensors.
KC KC Standardize ratio 1.0 ± 0.2
A/R KC should not drift more
than 0.01 units from
standardize to standardize;
drift could indicate dirt or
condensation on the
windows.
SIGMIR SIGMIR This is one standard 0.00005 ± 0.00005
deviation of noise. It is Values outside of this range
reported in percent of noise indicates head or cabling
of the A/R ratio. problems.
IRGAIN IRGAIN Preamp gain required to HemiPlus and Lt Hemi -
achieve the RAIR reading; 4±3
applies only to Hvy Hemi - 11 ± 3
transmission–type sensors If the gain changes, it is an
indication of dirt buildup,
changes in the chiller,
problems with the detector,
or lamp problems.


OptiPak Sensor
Table 6-24 Range for OptiPak Standardize Limits
Host Computer Variable Name In Variable Description Acceptable
Reporting Name OptiPak Health Range
Report
Full Scale Volts FULL Maximum output voltage of each Formation:
OptiPak component with 0.105 ± 0.025
nothing in the gap. VDC
NOTE: Due to lamp Opacity
brightness decay, the signal 5.0 - 9.5 VDC
strength may lose up to 15% Brightness:
in each year of operation. 1.0 - 4.5 VDC
Zero Volt ZERO Minimum output voltage of the 0.125 ± 0.025
Brightness and Opacity sensors VDC
with the source turned off.
Vacuum Volts Vacuum The vacuum signal with no 7.5 ± 0.146 VDC
process in the gap.
Ash Sensor
Table 6-25 Range for Ash Sensor Standardize Limits
Host Computer Variable Name In Variable Description Acceptable Range
Reporting Name Ash Health
Report
AIZ Zero Voltage with the electrometer clamped. 0.0 ± 1.0 VDC
SIGMAZ Zero Noise Standard deviation of the clamped <0.001 VDC
electrometer signal.
AISOUT Nominal Flag Out Voltage output of the electrometer with 7.3 ± 1.9 VDC
nothing in the gap.
SIGMAGO Noise Range - Standard deviation of the electrometer TBD
Flag Out output signal with nothing in the gap.
AISIN Nominal Flag In Voltage output of the electrometer with (45% to 85% of AISOUT)
nothing in the gap. ± 1.0 VDC
(See note below)
SIGMAGI Noise Range - Standard deviation of the electrometer TBD
Flag In output signal with nothing in the gap.
Note: After determining what the AISOUT value is, make sure that the
AISIN value falls to within the 45% to 85% range of AISOUT.
Determine the percentage by calculation. Set nominal for AISIN so
that it is the correct percentage of AISOUT.


Caliper Sensor
Table 6-26 Range for Caliper Sensor Standardize Limits (Continued on next page)
Host Computer Variable Name In Variable Description Acceptable Range
Reporting Name Caliper Health Report
SMAX Sensor Max Expected output voltage of Air Brng Cal:
the proximeter switch with 7.5-9.0 VDC
the heads unclamped GT Caliper:
8.25 VDC ± 1.0
SNOISE Sen Max Noise Standard deviation of the < 10 mv
maximum sensor signal
noise in mv
SZERO Sensor Zero Expected voltage of the Air Brng Cal:
proximeter output with 3.0-4.0 VDC
nothing in the gap and the
heads clamped. On GT Cont Cal
Caliper, this value is filtered (Al foot):
by the “Sensor Zero Filter 5.5-7.0 VDC
Factor Up/Down”
Cont Cal
(Ti foot):
3.5-5.0 VDC
GT Cal - 2.25
± 1.0 VDC
Sensor Zero Raw The unfiltered value of the GT Cal - 2.25
GT Caliper signal with the ± 1.0 VDC
probe closed. It is usually
determined from the GT
Caliper calibration report.
On GT Calipers calibration
reports without this variable,
it can be determined by
cleaning the probes and
doing a CLEAN standardize.
The value to use will be the
resulting measured Sensor
Zero.
Pressure Zero This is the output signal of GT Cal - 5.0 VDC -
Pressure Zero Top (GT) the pressure transducer when 7.0 VDC
Pressure Zero Bot (GT) there is no pressure being
applied to the probe. Other Calipers -
7.0 VDC - 9.0 VDC


Table 6-26 (Continued)

Host Computer Variable Name In
Reporting Name Caliper Health Report Variable Description Acceptable Range
Pressure Top Pressure at top and bottom 12.5 - 50 mb
Pressure Bottom heads of GT Caliper, with air
solenoids engaged, in milli-
bars.
Pressure transducer voltage Air Brng Cal:
difference in volts 1.2-2.0 VDC
PRESSURE Contact Press (globalPressure -
PressureZero) Cont Cal
0.2 - 0.3 VDC
Air Brng Pressure Air bearing voltage difference Air Brng Cal:
DSAIRB in volts (airBearingStats - 0.7-0.9 VDC
(air bearing sensorZero)
sensor only) Cont Cal:
0 VDC
ABNOIS Air Brng Press Noise Air bearing noise in mv < 5 mv
(air bearing
sensor only)
Vacuum Signal Vacuum signal voltage in volts Air Brng Cal:
VACREF 6.8-7.8 VDC
(air bearing
sensor only) Cont Cal:
NA


Gloss Sensor
Table 6-27 Standardize Limits for the Gloss Sensor
Variable Name In
Host Computer Gloss Health Acceptable
Reporting Name Report Variable Description Range
stdzAdjNominal Nominal value for limit 1.71 VDC
checking the maximum signal
output on air. It should be about
1.7 VDC.
stdzAdjRange Range limit of the maximum ± 1 VDC
signal output on air. It should
be set to 1 VDC.
stdzZeroOffset- Nominal value for limit 0.26 VDC
Nominal checking the minimum signal
output with the measurement
clamp. It should be about 0.06
VDC.
stdzZeroOffset-Range Range limit of the minimum ±.11 VDC
signal output with the
measurement clamped. It
should be set to 0.1 VDC.
stdzVacuumNominal Nominal value for limit 7.5 VDC
checking the head pressure
associated with the vacuum. It
should be about 7.5 VDC. Note
that increasing pressure
decreases the voltage.
stdzVacuumRange Range limit of the head pressure ± 1.5 VDC
associated with the vacuum. It
should be set to 1.5 VDC.


Verification
Background
Sensor verification is the process of determining if the measurement signals from
the sensor are being processed into correct measurement values at the Host. This
can be done in an uncomplicated manner by using standard check samples and
comparing the results of on line measurements to those known values.
If you have trouble verifying sensor performance, then you would want to use a
more vigorous methodology to examine sensor performance.
Initial verification of sensor performance can be accomplished using the Service
Workstation and the sensor Health Pages. Initial verification of the Moisture and
the Ash sensors cannot be done independent of the Host because setup specific
compensation factors must be set up at the Host. For long–term verification for
sensor performance, refer to the sensor verification procedures in your Host
documentation.
It is important to organize the sensor verification process into distinctive phases
with a different set of procedures and goals for each phase.
Phase I – Initial Static Verification
The purpose of this activity is to verify that the Smart Platform and its associated
sensors have been properly installed and adjusted and that all calibration constants
are correctly entered. During this phase, the measurement system is also tested for
stability and repeatability, to assure that it is ready to start the on–line measurement.
Typically, this program takes one day.
Phase II – Process Measurement Verification
This phase of the program has the goal of verifying on–line measurement during
dynamic conditions to the customer laboratory standards, on some of the key grades
of paper being run in the process. This phase is usually 1–4 weeks.
Phase III – Continuing Certification
The purpose of this phase is to assure that long–term measurement performance is
stable, and to alert about any potential problems before any degradation can happen
in measurement quality. This phase is organized to give a reliable long–term
performance record to the system by means of simple, periodic checks, and record
keeping. By definition, this phase lasts for the life of the system.


Implementation of the Sensor Verification Program

A major portion of Phase I can be implemented using only the Service Workstation
and the Smart Platform.
Activities include:
• Reading of all of the check samples
• Recording standardize stability
• Recording check sample repeatability
• Recording internal check sample readings
• Verifying calibrate sample function operation
• Scanning on air gap and on samples to verify static profiles (requires Host
system)
• Generation of Phase I verification results report.
Phase II and Phase III are implemented using mostly the Host computer reporting
and graphing packages.


Air Temperature Compensation for Basis

Weight
Air Temperature Compensation (ATC) corrects the basis weight measurement for
changes in air density due to temperature changes in the measurement column.
ATC measures the temperature at clean window standardize and then corrects the
basis weight measurement for deviations from the last clean standardize value at
each measurement.
Note: ATC should not operate while using the air gap conditioner (AGC).
Tune ATC with AGC turned off.
The temperature measurement is the weighted sum of four signals derived from
thermistors in four locations: Source head, Detector head, Air gap above the sheet,
Air gap below the sheet.
Tuning ATC involves:
• Verifying the measurement stability of the beta sensor
• Tuning ATC based upon its response to an artificially induced temperature
gradient
Verification of Setup and Stability
1. Access the inspect utility at the Service Workstation.
2. At the I> prompt type:
BetaSensor01->tempCompFlagExists=1
3. Save the change using the gstore utility.
4. Restart the system to complete the enabling process.
5. Use the Basis Weight Health Report to check the default values for
temperatureCoefficients coldstart file and compare them to the values in Table
6-28 for your specific sensor type. Update the coefficient array if it does not
match the values in the table. The default for dBWdT is shown in the table.
If it is different from that reported on the Health Page, then a previous
adjustment has been made. Do not change it at this time.


Table 6-28 Default Sensor Temperature Coefficients

Variable TLK5 TLK8 TLK9 TLP1
temperatureCoefficients 1 0.0 0.09765 0.1758 0.0
temperatureCoefficients 3 -0.3477 0.2813 0.0 0.1953
dBWdT -0.1 -0.1 -0.1 -0.1
6. Adjust the air pressure to the air wipes up to 35 psig (pounds per square inch
gauge).
7. Place the system in Sample Check Mode to verify off–sheet stability.
8. Move the sensor to the off–sheet position and let it stabilize for 10 minutes.
9. Clean the sensor windows and then perform a clean standardize.
10. Perform several sample checks without a sample in the air gap. Check the
values of PPT and STANDARD WT on the Sample Check Report.
• The specification for STANDARD WT is 0.0 ± 0.2 gram.
• The specification for PPT at clean standardize is 1000 ± 0.5.
If the values for STANDARD WT and PPT do not meet these
specifications, there is a basic problem with the basis weight measurement
such as:
• Broken or dirty window on the beta sensor
• Incorrect head constants
• Air Wipes are not set up properly
These conditions will have to be corrected before fine tuning ATC.
11. Take the system out of the sample check mode and turn on ATC by setting the
variable BetaSensor0x->tempCompFlag to 1.
12. Perform a clean standardize immediately after ATC is turned on.
13. Let the measurement heads scan over the process for approximately 30 minutes.
14. Move the heads to the off–sheet position. Perform several more sample check
measurements on air.
15. Compare the check sample readings before and after the air wipes are turned on.
The basis weight measurement from the check sample readings, before and after
the air wipes are turned on, should not vary by more than 0.2 G/M2.
If the basis weight measurement does not meet this specification, then fine tune it
by adjusting dBWDT. Refer to the procedure on page 159.


Fine Tuning ATC with dBWDT

Fine tuning ATC involves monitoring the measurement response to an artificially
induced temperature gradient. For this procedure you will need two people and a
800–1200 Watt heat gun. Using a larger heat source will damage the sensor heads.
Begin with the head package in the off–sheet position without a sample in the gap.
1. Position the heating device in the machine direction at the front of the sensor
package, exactly in line with the windows and parallel with the surface. Hold
the heat source steady and 12 - 18 inches away from the sensor. See Figure 6-14.
Heat Gun
Figure 6-14 Heat Source for Fine Tuning dBWdT

2. Turn on the heat source and let the temperature stabilize for one minute.
3. Perform several sample checks with the heat source on.
4. Average the values of the STANDARD WT from the sample checks.
The value of STANDARD WT, after heating the sensor, should be 0 ± 0.2 G/M2.
The value of PPT, after heating the sensor, should be 1002 to 1005 units. This
range indicates a reasonable temperature change. If the PPT value is greater
that 1005 units, reduce the heat.


5. Adjust the value of dBWdT using the following guidelines:

• If the STANDARD WT value is zero, leave dBWdT as is.
• If the STANDARD WT value is greater than +0.2, decrease the magnitude
of dBWdT.
• If the STANDARD WT value is less than - 0.2, increase the magnitude of
dBWdT.
Note: The range of dBWdT is -20 to 0. A more negative value of dBWdT

means more temperature compensation. A less negative value of
dBWdT means less temperature compensation.
6. Enter the new dBWdT and repeat the sample checks with the heat source On.
The STANDARD WT should be 0.00 ± 0.2.
If the ATC operation does not meet specifications, check the thermistor
operation.


Air Profile Compensation for

Basis Weight, Gloss, and Caliper
Perform the procedure only under the direction of a

measurement specialist.
Note: If you are planning to perform Air Profile Compensation for the
OptiPak sensor, you can set up the OptiPak sensor at the same as
Basis Weight, Gloss, or Caliper. Refer to the procedure “Air Profile
Compensation for Basis Weight, Gloss, and Caliper” on page 161.
Air profile compensation (APC) allows for any mechanical misalignments of the
platform without degrading the measurement performance. APC allows the sensor
heads to traverse the entire platform length, including off–sheet and standardize
position, without any process in the gap. During APC operation, the system gathers
deflection measurement data. This data can be used to smooth out any errors in the
measurement due to platform irregularities.
To use APC, first collect an air profile by setting a software flag and using Host
computer commands to begin air profile collection.
The system generates the air profile by scanning the widest sheet trim without a
process in the gap. The maximum trim limits (homeMeasureLimit and
farMeasureLimit) define the scanning limits while performing APC. To collect
enough information, the sensors must make at least five complete scans (forward
and reverse). When the scanning is complete, the sensors will move to the off–
sheet position. The scan limits are reset to the last known scan limits
(homeScanLimit and farScanLimit).
The number of forward and reverse scans set up for APC is defined by the Host as 10.
Air Profile Data Collection
Note: There must be an active sheet break to perform this function.
1. Disable the auto edge–of–sheet feature, if it is present and active.


At the Service Workstation

1. Turn the APC existence flag on by using the inspect utility in the Smart Platform
subsystem as follows:
At the I> prompt type:
betaSensor01->airProfileCompExists=1 (for basis weight)
caliperSensor01->airProfileCompExists = 1 (for caliper)
topGlossSensor01->airProfileCompExists=1 (for top gloss)
bottomGlossSensor01->airProfileCompExists=1 (for bottom gloss)
2. For the Gloss sensor, insert a sample of the most common grade into the sensor.
The air to the air bearing sheet guides must be turned Off and the sample must
be stretched very tightly without any ripples in the gap.
At the Host Computer
1. Enable APC through the Host computer.
The operator can abort the APC composite mode by selecting mode zero. The
system will alert the operator that enough data may not exist to perform APC.
2. Activate Scan at the Host computer.
The sheet–break override also activates and the sheet–break override alarm
results. When APC is complete, the sensors move to the off–sheet position.
3. Push the ON–SHEET push button at the platform.
4. Push the STDZ (standardize) button at the Host operator station. Wait for the
system to standardize.
5. Let the scanner go through at least five complete forward and reverse scans or
let it exit by itself.
6. Activate OFF–SHEET at the Host computer.
7. Exit the air profile collection mode.
8. Return the auto edge–of–sheet feature to the usual mode.
9. Change to the airProfile directory
cd/ss01/airProfiles
10. Type: Is -l
to list the contents of the directory. The directory should reflect the current
date, indicating that the data was successfully written to the file. Each sensor
will have a separate file of from 1,000 to 2,000 bytes in the airProfile directory.
11. Remove the paper from the Gloss sensor gap.
12. Save the existence flag to the scanner community diskette using the gstore
utility.


Enabling Air Profile Compensation

1. Turn APC on by using the inspect utility as follows:
betaSensor01 -> airProfileCompOn=1
CaliperSensor01 -> airProfileCompOn = 1
topGlossSensor01 -> airProfileCompOn=1
bottomGlossSensor01 - > airProfileCompOn=1
2. If this is to be the normal mode of operation, save the flag on diskette by using
the gstore utility.


Air Profile Compensation for OptiPak
Perform the procedure only under the direction of a

measurement specialist.
Setup
Air Profile Compensation for OptiPak is only run for opacity and brightness.
1. Use the Health Reports to view the values of the standardize limits for OptiPak.
2. Record the nominal values. You will need to re–enter them later.
3. Place a sample of the process that simulates the typical process in the gap of
the OptiPak before requesting a standardize.
Leave the paper in the gap while running Air Profile Compensation.
4. Request a standardize.
5. Enter the new standardize nominal values into genrpt or the OptiPak Health
Report so that the OptiPak sensor will pass standardize.
6. Perform another standardize.
7. Turn On the APC existence flags using the inspect utility.
OpacityAir ProfileCompExists=1
BrightnessAir ProfileCompExists=1
1. Enter the Air Profile Compensation Initial Air Mode.
2. Request the Scan mode.


Data Collection
At the Platform
1. Push the ON SHEET push button at the platform. The head will start to scan
from the home measure limit to the far measure limit.
Note: The number of scans that occur during data collection are defined
by the Host as 10.

2. Exit the Air Profile Compensation Mode at the Host computer.
3. Change to the airProfile directory
cd/ss01/airProfiles
4. Type: ls -l
to list the contents of the directory. The directory should reflect the current
date, indicating that the data was successfully written to the file.
Each sensor will have a separate file of from 1000 to 2000 bytes in the airProfile
directory.
5. Remove the paper from the OptiPak sensor gap, restore the nominal standardize
limits in the Health Report, and request a standardize.
6. Save the changes using the gstore procedure.
The Air Profile Compensation Setup procedure is now complete.
Using the Data
1. Turn the Air Profile Compensation On by using the inspect utility as follows:
After the I> prompt type:
OpacityAirProfileCompOn=1
BrightnessAirProfileCompOn=1
2. Save the changes using the gstore utility.


Digital Input Invert Adjustment for the

Smoothness Sensor
The first Smoothness sensor on the Smart Platform (smoothness Sensor A01) must
have the two digital inputs for temperature alarm and validity, inverted before being
processed by the MPRC software. To do this, proceed as follows:
1. Activate the dim utility.
2. Select the digital inputs for the ucGeneral board.
3. Invert bit 0 by pressing i, then 0, then <return> twice.
Observe that the Invert bit gets set and that the value changes to a 1.
4. Repeat step 3 for bit 1.
5. Press q and respond affirmatively when asked if the mask changes are to be used.
6. Press q repeatedly until $$ prompt returns. Do a gstore to the io community
to save the information.


Default Compensations for IR Moisture,

Microwave, and Ash Sensors
IR Moisture, Microwave, and Ash sensors are dependent sensors requiring
compensation from other process parameters. The requirements for each sensor
are as follows:
Table 6-29 Default Compensation Requirements
Dependent Sensor Compensation Required
Basis Weight (in 2-Filter mode)
IR Moisture Sensor
Ash (in HemiPlus mode)
Basis Weight
Microwave Sensor
Sheet Temperature (optional)
Basis Weight
Ash Sensor
Moisture
Each of these sensors must have their compensating input values established within
the Host Computer Grade File for each customer grade, even if the sensor has been
configured to use the internal (measured) value for its compensation. This is so
that, if the internal (measured) value becomes unavailable for one reason or another,
there will be a reasonable compensation signal available for the dependent sensor
coming from the Grade File. Refer to the Host computer documentation for details
on setting up the respective Grade Files.


Calibrate Sample - Minimum Time Data

Accumulation
The Calibrate Sample function provides a real-time report of the active measurement
performance of all the operational sensors on the Smart Platform. The data
collection operates in parallel with the normal measurement processing taking place
so that there is no interference with data being delivered to the host computer system.
The Calibrate Sample procedure is available any time the measurement head is on-
sheet and measuring.
There are two methods of operation:
• Holding the Calibrate Sample push button down for the duration of the data
collection. The Calibrate Sample push button is the “scissors” push button
located on the Frame Control Panel. You can hold down the push button for as
long as desired, with no upper limit.
• Press and release the Calibrate Sample push button and allow the internal timer
to dictate the duration of the data collection.
The default time in the inspect utility shows up as a 0, which the system converts
to a minimum time of five seconds. To make this time longer, follow the steps
below:
2. Check the current minimum Calibrate Sample time by typing:
fhi01 →calSampMinTime
If a 0 or less than 5, the minimum time will be five seconds.
3. Enter in the desired minimum sample time:
fhi01 → calSampMinTime=xx
Where: xx is any time greater than five seconds.
4. Verify the change by placing the head on-sheet and measuring. Then, press
and release the Calibrate Sample push button. The push button LED should
remain lit for the time just entered in Step 4 plus a five-second settle time.
5. Save the change by performing a gstore to the Frame Human Interface
Community (fhi01).


7
Control Panel Operation
The basic operations of the Smart Platform are managed by the control panel. This
chapter describes the operations that can be performed using the control panel.
Section............................................................................................... Page
Control Panel Description ............................................................................. 170
Smart Platform Modes of Operation ............................................................. 171
Control Panel Functions ................................................................................ 173
Head Split Switches ....................................................................................... 177
101764-003 Control Panel Operation 169


Control Panel Description

The control panel consists of a covered key pad with 12 keys and two sensor shutter
indicator lights. A control panel is located on each end column of the Smart
Platform. Refer to the control panel in Figure 7-1.
Shutter Closed Shutter Open

Indicator Indicator
Off Sheet On Sheet Enable
Local Remote
Jog Reverse R F Jog Forward
Calibrate Sample Sample Check
Clean Standardize Maintenance
Set Reverse Limit R F Set Forward Limit
LED located on R
each push button
Figure 7-1 The Smart Platform Control Panel

When a control panel push button has been pressed, the request is acknowledged
by a small LED located in the upper left corner of the button, as shown in
Figure 7-1. For some control panel push buttons, the LED will remain on while the
push button is being pressed or while a function is being performed. For other
control panel push buttons, the LED will remain on until another push button has
been pressed, placing the Smart Platform in another mode.
170 Control Panel Operation 101764-003


Smart Platform Modes of Operation

The control panel has four modes of operation that allow different levels of Host
computer control. The control panel’s modes of operation are described below.
Remote/On-Sheet
In the Remote/On Sheet mode, the Host computer has total control of the Smart
Platform. The Host computer is able to request the Smart Platform to measure,
standardize, or other remote operations.
While the Smart Platform is in the Remote/On Sheet mode, the REMOTE and ON
SHEET push button LEDs are on.
Remote/Off-Sheet
In the Remote/Off-Sheet mode, the Smart Platform is still communicating with the
Host computer system, but it will refuse any Host requests to measure or
standardize, but permits sample check.
While the Smart Platform is in the Remote/Off–Sheet mode, the REMOTE and
OFF SHEET push button LEDs are on, and the sensor head package is in the off-
sheet position on the Smart Platform.
When a sheet break is detected on the paper machine, the sensor shutters close, the
sensor head package moves to the off–sheet position, and the Smart Platform enters
the Remote/Off–Sheet mode automatically. Head tracking errors, inherent sheet
break, and AEOS errors will also cause the platform to automatically enter the
Remote/Off–Sheet mode.
The Smart Platform must be in the Remote/Off–Sheet mode to perform sensor
sample checks. While in the Remote/Off–Sheet mode, the STANDARDIZE push
button on the Smart Platform control panel is enabled, but any standardize results
will be reported through the Service Workstation, not the Host computer.
Local
In the Local mode, all communications with the Host computer are disabled. The
sensor shutters will not open and the Smart Platform will not scan.
When the Smart Platform is in the local mode, the LOCAL push button LED is on
and the On Sheet and Off–Sheet LEDs are off.
The Local mode enables the control panel JOG and SET SCAN LIMIT push
buttons.


Local/Head Split
In Local/Head Split mode, all communications with the Host computer are disabled,
and the Smart Platform drive mechanism is disengaged.
The Smart Platform enters Local/Head Split mode when the drive clutch is
disengaged by a head split switch, located in each of the Smart Platform end
columns. The Smart Platform also enters this mode when the air supply to the drive
clutch drops below the correct pressure.
Since the drive mechanism is disabled in local/head split mode, the sensor head
package can only be positioned by hand.


Control Panel Functions

The functions of each of the control panel push buttons is described below.
Off-Sheet
If the Smart Platform is in remote, pressing the OFF SHEET push button places
the Smart Platform in Remote/Off–Sheet mode.
If the OFF SHEET push button is pressed while the Smart Platform is scanning or
standardizing, the sensor shutters close and the head package moves to the off–
sheet position.
On-Sheet
If the Smart Platform is in remote, pressing the ON SHEET push button places the
Smart Platform in Remote/On Sheet mode. When the ON SHEET LED is lit, it
permits the Host to direct the head to standardize or measure.
Local
Pressing the LOCAL push button places the Smart Platform in Local mode.
If the Local push button is pressed while the Smart Platform is scanning or
standardizing, the sensor shutters close and the head package remains in place.
Remote
Pressing the REMOTE push button places the Smart Platform in Remote/Off-Sheet
mode, if the Smart Platform is currently in Local mode.
R F
Jog
The JOG push buttons are used to position the sensor head package manually,
anywhere between the mechanical limit switches of the Smart Platform. The
FORWARD JOG push button (F) moves the head package towards the far side end
column. The REVERSE JOG push button (R) moves the head package toward the
home end column.
The JOG push buttons only function when the Smart Platform is in Local mode.


Calibrate Sample (Sample Cut)
While the CALIBRATE SAMPLE push button is pressed, the Smart Platform begins
a special accumulation of measurement single point or profile data. When the push
button is released, this data is forwarded to the Host computer where a Calibrate
Sample report is printed.
The CALIBRATE SAMPLE push button LED is on while the measurement data is
being accumulated, and while the data is being sent to the Host computer.
The CALIBRATE SAMPLE push button functions only when the Smart Platform
is measuring in the Remote/On Sheet mode and the sensor is in the measurement
mode, either scanning or in single point.
Sample Check
The SAMPLE CHECK push button requests the sensors to take a sample check
measurement. The push button LED is on while the measurement is being taken.
The SAMPLE CHECK push button operates only if the Smart Platform is in the
Remote/Off-Sheet mode. No report will be sent unless the Sample Check mode is
enabled at the Host computer. However, a local report is available through the
Sensor Health Report.
Standardize
Pressing the STANDARDIZE push button requests the sensors to perform a

standardize. The standardize will be either CLEAN or DIRTY depending on the
setting of the localStdzType instance variable in the fhi01 object. The push button
LED is lit during the standardize cycle. If any of the sensors fail the standardize,
the LED flashed until the sensors all pass standardize. Standardize reports are
available through the HOST display, or through the HEALTH PAGES at the Service
Workstation.
The sensors will do a CLEAN or DIRT standardize depending on the state of the
defaultStdzType flag associated with each sensor object. If the flag is a “0”, the
standardize will be a DIRT one. If the flag is a “1”, then the standardize will be a
CLEAN one. The only sensors affected by a CLEAN or DIRT request are Basis
Weight, Caliper, and OptiPak. For the other sensors, this discussion is irrelevant.
They will do their normal standardize no matter what the flags are set to.
It is possible to temporarily change the Control Panel default standardize mode from
DIRT to CLEAN by setting the localStdzMode flag in the fhi01 object object to a
“1”. This assignment is set back to DIRT (“0”) automatically at the next restart.


Self Test
The Self Test push button serves as a lamp test for the LEDs on the panel, as well
as being able to initiate a check on the positioning subsystem operation when the
scanner is in the LOCAL mode. In all scanner modes except LOCAL, when the
Self Test push button is pushed, the various LEDs on the panel will sequentially
light up momentarily to indicate their condition. This test has no impact on what
other functions the scanner is performing at the time.
When the scanner is in LOCAL, the function of the Self Test push button changes
to include a check on the positioning subsystem. Under the LOCAL condition, the
initial push of the button will start the usual LED lighting cycle, but when released,
the OFF SHEET LED will extinguish and the scanner will attempt to resynchonize
the encoder. The following sequence will take place.
• unsynchronizes the encoder
• moves the head package to the home limit switch
• resynchronizes the encoder
• moves the head package to the off-sheet position
Note: The test can be started with the head located anywhere along the
frame. When the test starts the head will move toward the home
limit switch at a high slew rate. If there is a need to stop the head
at any time during this transition, simply press the LOCAL push
button once more, stopping the head. This will terminate the self-
test request.
The actual check being performed in this test, is to verify that the encoder count at
the point of the head coming off the limit switch, matches the count when the
encoder was initially synchronized. Any error in this will result in the push button
LED flashing. In this case, run the test again to clear the alarm and check the
Encoder Diagnostic screen in the ft utility to see the details of the encoder’s history.
It is possible that the test failure may only be the result of the system having lost
some counts during an earlier scan. In that case, the Encoder Diagnostic screen
should be visited periodically to make sure that the condition is not a chronic one.
Some things which can cause failure are:
• Scanning too fast (can lose encoder counts)
• Defective encoder
• Defective encoder mounting (slipping)
• Defective cabling from encoder to the ECF board
• Defective ECF board


R F Scan Limit Set
The LIMIT SET push buttons set the measured sheet edge limits for Smart Platforms
without auto edge–of–sheet (AEOS) or when AEOS is disabled.
The FORWARD LIMIT button (F) sets the limit near the drive (far) end column of
the Smart Platform. The REVERSE LIMIT button (R) sets the limit near the idler
(home) end column.
The LIMIT SET push buttons are enabled only when the Smart Platform is in Local
mode.


Head Split Switches

To gain access to the sensors mounted in the Smart Platform head package, a head
split switch is located in each end column, as shown in Figure 7-2. The switch,
when activated, disengages the motor drive clutch and allows the top and bottom
sensor heads to be separated.
Head
Split
Switch
Drive End Idler End
Figure 7-2 Locations of the Head Split Switches

When the sensor heads are split, the Smart Platform is placed in Local mode, and
the sensor heads can only be moved by hand.


Make certain the sensor heads are properly aligned

before re–engaging the clutch. Aligning the sensor
heads is mandatory to assure the radiation beam is
directed to its proper target.
In Local/Head Split mode, all communications with the Host computer are disabled,
and the Smart Platform drive mechanism is disengaged.
The Smart Platform enters Local/Head Split mode when the drive clutch is
disengaged.
Make sure the sensor heads can be separated by manually moving the bottom head.
Since the drive mechanism is disabled in Local/Head Split mode, the bottom sensor
head package can only be positioned by hand.


8
Startup Options
There are two startup options available to the user, one requires manual intervention
after the reset is initiated, and the other is automatic in that the startup sequence
will proceed automatically after a power reset or a manual reset request. It is
recommended that the switch be left in the automatic startup position. The manual
position is used primarily for troubleshooting activities.
Section............................................................................................... Page
Manual Startup .............................................................................................. 180
Automatic Startup .......................................................................................... 181
Service Workstation Software Startup ........................................................... 182
101764-003 Startup Options 179


Manual Startup
The following procedure involves manual intervention via the console keyboard
after reset has been initiated. It also enables reporting of conditions resulting in an
OFFLINE DEBUG status of the software.
1. Place the START MODE switch on the MPRC front panel to the STOP/DEBUG
position (down).
2. Either press the RESET switch on the MPRC front panel, or type reset on the
console keyboard (Smart Platform window open).
3. For non-Ethernet MPRC Boards (086349-002):
When the console responds with OFFLINE DEBUG, enter a g {CR}.
For Ethernet MPRC Boards (086444-001):
When the console responds with OFFLINE DEBUG, place the START
MODE switch back to the center position, then enter a g {CR}.
4. The system will proceed with the startup and loading activity after about a 15-
second delay for diagnostic checks.
5. In less than a minute, the console should display the startup completion banner
which gives the download instructions from the Host computer. Execute the
PMMRLD command directed by the Host computer.
6. The Host computer download activity will result in three messages:
pmmFrame01: HOST TO AMS DOWNLOAD IN PROGRESS.
pmmFrame01: HOST TO AMS DOWNLOAD COMPLETED.
pmmFrame01: HOST COMMUNICATIONS ESTABLISHED.
If the download activity is not started, the console will eventually respond with:
pmmFrame01: HOST COMMUNICATIONS TIMEOUT.
180 Startup Options 101764-003


Automatic Startup
This method of startup will automatically restart the Smart Platform MPRC board
in the case of a power reset or a manual reset request.
1. Place the START MODE switch on the MPRC front panel to the Short Diag
position (middle).
2. Either press the RESET switch on the MPRC front panel, or type reset on the
console keyboard (Smart Platform window open).
3. The system will proceed with the startup and loading activity after about a 15-
second delay for diagnostic checks.
4. In less than a minute, the console should display the startup completion banner
which gives the download instructions from the Host computer. Execute the
PMMRLD command as directed by the Host computer.
5. The Host computer download activity will result in three messages:
pmmFrame01: HOST TO AMS DOWNLOAD IN PROGRESS.
pmmFrame01: HOST TO AMS DOWNLOAD COMPLETED.
pmmFrame01: HOST COMMUNICATIONS ESTABLISHED.
If download activity is not started, the console will eventually respond with:
pmmFrame01: HOST COMMUNICATIONS TIMEOUT.
101764-003 Startup Options 181


Service Workstation Software Startup

1. Connect the Service Workstation serial port to the Smart Platform 1200.
2. Load up the software ACE2/GONZO and HEALTH diskettes into the Service
Workstation per instructions in the Smart Platform System Software Manual,
101760-00x.
3. Select the Smart Platform “HEALTH/ACE2 TERMINAL” window to get the
AVOS window.
4. Press return to display the $$ prompt.
182 Startup Options 101764-003


9
Maintenance Procedures
Section............................................................................................... Page
Smart Platform Maintenance Log ................................................................. 184
Inspecting the Incoming Power ..................................................................... 186
Inspecting the Drive System .......................................................................... 187
Wheel Inspection ........................................................................................... 195
Platform Alignment Inspection ..................................................................... 196
Air Purge Filter Inspection ............................................................................ 197
Inspecting the Compressed Air Filters .......................................................... 199
Inspecting the Water Filter ............................................................................ 200
Power and Temperature Checks .................................................................... 201
101764-003 Maintenance Procedures 183


Smart Platform Maintenance Log

(Initial Maintenance) START DATE: ___________
MAINTENANCE ITEM SCHEDULE (WEEKS)
1 2 3 4 5 6 7 8 9 10 11 12
DRIVE CHECKS
1. Check upper/lower drive

belts with tensiometer. 1
2. No evidence of wear or
cracks in belts
3. Motor Drive Belt Tension
(Tight enough to eliminate
possibility of the belt
derailing)
4. Upper/lower Seal Belt

Tension (uniform seal
provided and no gaps in
seal exist) 2
5. Head Separation Clutch

Operation
WHEEL CHECKS
1. Upper/lower Carriage
Wheels

Roller Assembly
ALIGNMENT CHECKS
1. Air Profile Check 3
2. Scan Direction Alignment
UTILITY CHECKS
1. Air Purge Filter
2. Compressed Air Filters
3. Water Filter
1 Check upon replacement and at three weeks after replacement.
2 Check upon replacement and at one week after replacement.
3 Check at four week intervals when the process is not running.
184 Maintenance Procedures 101764-003


SMART PLATFORM MAINTENANCE LOG

(Subsequent Maintenance Log) START DATE: ___________
SCHEDULE (MONTHS)
MAINTENANCE ITEM
1 2 3 4 5 6 7 8 9 10 11 12
DRIVE CHECKS
1. a.Check upper/lower drive

belts with tensiometer.
b. Check pulleys for lubrication
c. Check belt tracking on
page 188.
1
2. No evidence of wear or
cracks in belts
3. Motor Drive Belt Tension

(Belt should deflect .12 - .25 in.
(3.0 – 6.3 mm) with finger
pressure)

Tension (uniform seal
provided and no gaps in
seal exist) . See page 191. 2
5. Head Separation Clutch
Operation/lubrication. See
page 193.
WHEEL CHECKS
1. Upper/lower Carriage
Wheels

Roller Assembly
ALIGNMENT CHECKS
1. Air Profile Check 3
2. Scan Direction Alignment
UTILITY CHECKS
1. Air Purge Filter. See
page 197. 4
2. Compressed Air Filters. See

page 199. 4
3. Water Filter. See 4

page 200.
1 Check upon replacement and at three weeks after replacement.
2 Check upon replacement and at one week after replacement.
3 Check at one month intervals when the process is not running.
4 Schedule for maintenance depends upon installation circumstances and mill conditions.


Inspecting the Incoming Power

The following procedure provides direction on checking the incoming power used
for the Smart Platform.
Verify the presence of incoming power at the idler end column. The power for the
Smart Platform comes through a transformer. The voltage to the transformer must
be of a nominal level (200, 208, 220, 230, or 240 volts) to connect to one of the taps
on the primary. The long–term variations from the nominal voltage must not exceed
± 10%.
Example: A 240 volt primary voltage must not average less than 198 VAC
or greater than 242 VAC for longer than one second.


Inspecting the Drive System

The drive system consists of several belts that must be checked periodically for
proper tension and damage or defects. Complete the following procedures to
perform the drive checks.
When performing any maintenance operation in the

carriages, always lock out the drive motor power
using the lock-out switch at the drive end column.
MOTOR ONLY
A
B
B
Lock Out
Switch
Figure 9-1 SP1200 Lockout Switch


Drive Belt Tension Measurement

Inspect the tension of the upper and lower drive belts. They should be the same.
Perform the belt tension check as follows:
1. Squeeze the handle of the tension gauge and place it on the drive belt at the
idler end of the Smart Platform.
The gauge must be applied to the portion of the carriage drive belt that traverses
the Smart Platform.
2. Release the handle and read the tension indication on the gauge. The tension
should be in the range specified on the gauge.
3. If the tension is outside of that range, adjust the idler pulley tension adjustment
screws until the tension is proper.
4. Tighten the adjustment lock when finished.


Drive Belt Tension and Tip Adjustment

Observe the idler pulleys on the Smart Platform while the sensor heads are scanning.
If the drive belt climbs up or down on the idler pulley, adjust the pulley tip by
completing the following steps:
1. Loosen the tip adjustment lock.
2. Tighten the tip adjustment if the belt tracks to the upper edge of the pulley.
3. Loosen the tip adjustment if the belt tracks to the lower edge of the pulley.
4. Observe the idler pulleys while the sensor heads are scanning. If the drive belt
climbs up or down on the idler pulley, repeat Step 2 or 3.
5. Tighten the tip adjustment lock.
Idler End Pulley

Tension Adjustment
Locks
Idler End Pulley

Tension
Adjustments (2)
Top View
Pulley Tip
Adjustment Pulley Tip
Locks Adjustments
Pulley Tip Assembly
Bottom View
Figure 9-2 Drive Belt Measurement and Adjustment


Drive Motor Belt Inspection

1. Inspect the upper and lower drive belts for evidence of wear or damage.
2. If either the upper or lower drive belt exhibits serious cracks, replace both drive
belts. Replacing both belts will prevent uneven wear of the belts. Cracks may
indicate a future failure of the drive belt.
3. Inspect the tension of the drive motor belt by pressing it with your finger. If a
deflection greater than 0.25 in. (6 mm) occurs, adjust the drive motor position.
Drive Motor Adjustment
1. Loosen the four drive motor/gear box mount adjustment bolts.
2. Slide the assembly away from the drive shaft to tighten the belt.
3. Tighten the assembly while keeping tension on the belt. The assembly should
remain parallel to the drive shaft at all times.
4. Inspect the drive motor belt for evidence of wear and cracks.
5. Replace belts that have evidence of wear or cracks.
Note: A spare belt can be attached to the shaft with tie wraps or heavy–
duty tape to make future service easier.
Drive Motor
Gear Reducer
Assembly
Adjustment Adjustment
Bolts
Figure 9-3 Drive Motor Belt Check and Adjustment


Seal Belt Tension Inspection

Inspect the seal belts. The seal belts must have enough tension so that a seal is
present along the length of the platform but not too much so that the carriage seal
belt roller is deflected up causing a break in the cable seal. Refer to Figure 9-4.
The tension on the seal belts must be even on each side of the belt. If this is not
the case, the carriage seal belt roller will be deflected up on one end.
Seal Tension Seal Belt

Adjusted Too
Tightly Carriage Seal
Belt Rollers
Extrusions
Seal Tension
Adjusted
Unevenly
Seal Belt
Seal Tension
Adjusted
Properly Seal Belt
Figure 9-4 Seal Belt Tension Checks


Seal Belt Tension Adjustment

Seal Belt Clamp

Adjustments
Seal Belt Clamp
Seal Belt
Figure 9-5 Seal Belt Adjustment

1. Inspect the seal belts for evidence of wear or cracks. Replace belts that have
evidence of wear or cracks.
2. Inspect the seal belt rollers for evidence of cracks or wear.
3. Inspect the spring tension on the seal belt rollers. The roller assembly should
exert some downward force when manually lifted. If this does not happen, the
roller assembly should be replaced.
If the seal belt tension is uneven, adjust the tension of the seal belt as follows:
1. Loosen the seal belt clamp adjustment corresponding to the side that is elevated
by a slight amount.
2. Tighten the clamp when finished.
If the belt tension is too tight at both sides:
1. Loosen the seal belt clamp adjustments and pull the seal belt evenly in the cross–
machine direction to result in a uniform decrease in tension.
2. Tighten the clamps when finished.


If the belt tension is too loose:

1. Loosen the seal belt clamp and pull the seal belt through the clamp in the cross–
machine direction evenly to result in a uniform increase in tension.
2. Tighten the clamp when finished.
Head Separation and Limit Switch Inspection
Refer to Figure 9-6 on page 194. Verify the operation of the head separation clutch
by completing the following:
1. Move the sensor head package to the off-sheet position.
2. Place the platform in Local by pressing the LOCAL push button on the control
panel.
3. Verify that the shutter closes on the Basis Weight and Ash sensors.
4. Activate the head separation switch located at either end of the Smart Platform
in the service outlet box.
5. Make sure the sensor heads can be separated by manually moving the bottom
head.
6. Move the sensor heads back as close as possible to their original position.
7. Deactivate the head separation switch by returning it to its normal position.
8. Manually position the sensor heads to make sure the air clutch has been properly
seated and locks when the proper position is reached.
9. Return to the normal system operation.
10. Manually jog the sensor package to the drive and idler ends slowing the rate of
travel as they reach the end of the platform.
11. Verify that the drive motor stops when the limit switch is tripped.


Head
Split
Switch
Drive End Idler End
Figure 9-6 Head Separation Check


Wheel Inspection
The carriage wheels should be checked periodically for wear or damage in the
material. Complete the following steps to check the carriage wheels:
1. Put the Smart Platform in Local mode.
2. Jog the sensor package to the drive end of the Smart Platform so that the carriage
wheels are visible at that end.
3. Check for proper wheel and way bar contact.
4. Jog the sensor package slightly to inspect portions of the wheel that are hidden
by the carriage.
5. Replace carriage wheels that exhibit wear or damage.
6. Jog the sensor package to the idler end of the Smart Platform so that the carriage
wheels are visible at that end.
7. Check for proper wheel and way bar contact.
8. Jog the sensor package slightly to inspect portions of the wheel that are hidden
by the carriage.
9. Replace wheel assemblies that exhibit wear or damage.
When performing maintenance operations to the

carriage or platform, always lock out the drive motor
power on the lock–out switch at the drive end
column.
MOTOR ONLY


Platform Alignment Inspection

The alignment inspection recommended for the Smart Platform consists of running
an air profile at four–week intervals during a time when the process is not running.
Complete the following to perform an air profile:
1. Scan the sensor package with at least ten scans without the process in the gap.
The composite profile weighting factor should be set up for 10 scans.
2. Select and observe the Basis Weight profile on the video monitor.
3. Compare the profile to the profile taken at installation. They should not differ
more than 0.1 grams per square meter (g/m2). Consult your measurement
specialist if the profiles differ more than this amount.


Air Purge Filter Inspection

The Smart Platform requires a constant flow of filtered air to keep the electronics
and mechanisms at a safe temperature and to prevent contaminants from entering
the sealed platform.
If the platform is utilizing DC motor cooling air from the mill air system, there are
no extra filters needed.
If the platform is using the ABB supplied high capacity purge blower (Part Number
101495-006, the filters need to be cleaned periodically to maintain good air flow.
The frequency of cleaning the filters depends upon mill conditions. The presence
of good air flow is easily detected by opening the doors on the idler side of the
Smart Platform.
The high capacity purge blower is intended to provide better SP Frame reliability
under all environmental conditions. The circuit breaker is rated at 15.0A for the
high capacity purge blower. The high capacity purge blower draws between 5 and
9 AMPs at 230 VAC during normal operation. The highest current will be observed
when the damper is fully open.
Purge Blower Replacement Process
Note: Purge blowers used before October 1995 used a low capacity purge
blower, Part Number 101495-003. This item is no longer being
used. A high capacity purge blower, Part Number 101495-006 is
now being shipped and replaces the low capacity purge blower.
If the low capacity purge blower fails, you will need to order the high capacity
blower assembly. The following assemblies are available for specific application
requirements:
• 123595-008 Purge Blower Assembly without cabinet and with
High Capacity Purge Blower
• 127323-011 Blower Assembly without cabinet and with
• 127323-012 Blower Assembly with stainless steel cabinet and
Note: Some earlier shipments of the high capacity purge blower contained
the wrong circuit breaker. If you replaced the low capacity purge
blower with the high capacity purge blower, check the circuit breaker
for the correct rating. If you are experiencing startup or run trips,
check the circuit breaker rating. If incorrect, order the correct rating,
15.0 A, ABB Part Number 014847-108.


Cleaning the Air Purge Filter

Cleaning the Air Purge Filter depends on the paper dust levels. If there is a high
level of dust, the filter should be checked and cleaned at least once a day. If there
are lesser amounts of paper dust, then the interval should be a minimum of every
other day.
If the Air Purge Filter requires frequent cleaning, you might consider relocation of
the blower to a cleaner environment. Failure to check and clean the filter will cause
premature failure of the purge blower motor and frame down time.
1. Turn off power to the purge blower using the switch on the blower.
2. Turn off the power at the power distribution center.
3. Remove the cylindrical fiber filter.
4. Blow compressed air into the inside of the filter to clean it. If the metal screen
filter is also dirty, clean it the same way.
5. Replace the filter. Restart the blower.
Note: Keep the Smart Platform well sealed and the doors fully closed at
all times, except during maintenance. Positive air flow is required
for reliable operation.


Inspecting the Compressed Air Filters

The Smart Platform requires good quality compressed air. Air pressure to the
platform must never be below 4.5 bar (65 psi). Contaminants are filtered through
the incoming air filters. The frequency with which the compressed air filters are
changed depends upon the amount of contaminants in the mill air supply and the
type of filter used. Inspect the filter once a week for the first three weeks to gauge
the frequency that the filter needs to be cleaned.
Cleaning the Compressed Air Filter
1. Press the OFF SHEET push button on the control panel.
2. Turn off the main AC circuit breaker at the Smart Platform idler side power
entrance module.
3. Turn off the main air valve.
4. Replace or clean the filter.
5. Turn on the main air valve.
6. Turn on power to the platform. Wait five minutes for stabilization, then perform
a standardize.


Inspecting the Water Filter

The maintenance schedule for the water filter will depend upon the amount of
contamination in the cooling water supply. Inspect the filter once a week for the
first three weeks to gauge the frequency that the filter needs to be cleaned. Follow
the procedure below for maintenance to the water filter.
1. To perform maintenance that will take two hours or more, turn Off the main
AC circuit breaker.
2. When maintenance will be less than two hours, keep the Liquid Cooling Unit
(LCU) pump running and the platform scanning, while temporarily shutting
down the mill water supply for filter replacement.
The replacement procedure for the water filter will depend upon what type of unit
was purchased.


Power and Temperature Checks

Prepare weekly reports on the system power and board temperatures. Use the
Electronics Health Pages to print out the last 20 occasions of DC power levels and
cabinet temperatures. Refer to Figure 9-7 for an example of the Electronics Health
Page. Keep the weekly reports in a log for future reference.
Electronics Health Report

Head Command: OFFSHEET System Alarms NO
Battery Memory: OK Active Alarms:YES
Board: FRAME ECF

Date Time Temp A/D Test +15 -15 Therm +5
°C Volts Volts Ref Volts
Jan 25 22:18 34.9 5.00 15.10 -14.96 4.90 4.96
Jan 26 16:43 34.4 5.00 15.02 -14.96 4.90 4.96
Jan 26 16:45 34.9 5.00 15.02 -14.96 4.90 4.96
Jan 26 16:59 35.4 5.00 15.02 -15.01 4.90 4.96
Jan 27 17:00 34.9 5.00 15.02 -15.01 4.90 4.96
Jan 28 0:40 34.9 5.00 15.02 -14.96 4.90 4.96
Jan 29 0:42 34.9 4.96 15.10 -14.96 4.90 4.96
Jan 29 10:15 34.4 5.00 15.02 -15.01 4.90 4.96
Jan 29 10:16 34.9 5.00 15.02 -14.96 4.90 4.96
Jan 29 10:54 35.4 5.00 15.02 -14.96 4.90 4.96
Jan 29 14:26 35.9 5.00 15.02 -15.01 4.90 4.96
Jan 29 14:36 36.4 5.00 15.02 -14.96 4.90 4.96
Jan 29 14:50 36.9 5.00 15.02 -15.01 4.90 4.96
Jan 29 15:25 37.4 5.00 15.10 -14.96 4.90 4.96
Jan 29 22:35 37.9 5.00 15.02 -15.01 4.90 4.96
Jan 30 15:35 35.9 4.96 15.02 -14.96 4.90 4.96
Jan 30 15:38 35.4 5.00 15.02 -15.01 4.90 4.96
Jan 30 15:53 36.4 5.00 15.02 -14.96 4.90 4.96
Jan 30 18:44 36.9 5.00 15.02 -14.96 4.90 4.96
Jan 30 20:41 37.4 4.96 15.02 -15.01 4.90 4.96
Esc F1 F2 F3 F4 F5 F6 F7 F8 HOME END PGUP PGD

EXIT HELP ALARM DATA PRVRP QUAL PRTSC PG 1 PG n PRVPG NXTPG
Figure 9-7 Electronics Health Page Report


DC Voltage Level Checks

Check the five DC voltage levels. Perform this check at least once a month using
the Electronics Health Page. The Electronics Health Page reports the number of
times each day that the DC voltages exceeded their tolerance limits. The limits are
checked on the hour, each hour of the day. The limits for each voltage are as follows:
± 12 volt supply - 11.41 - 12.64 VDC
+ 5 volt and +5 volt supply - 4.76 - 5.29 VDC
+ 10 volt supply - 9.94 - 10.12 VDC
Cabinet Environmental Checks
Check the cabinet environmental temperature at each microcontroller board.
Perform this check at least once a week using the Electronics Health Page. The
report represents the maximum temperature of each shift for each day. The limits
are checked on the hour, each hour of the day.
Examine the report for excessive cyclical variations or heating trends. It may be
possible to correlate performance problems with heat problems.


10
Replacement Procedures
Section............................................................................................... Page
Drive Motor Belt ........................................................................................... 204
Carriage Drive Belt ........................................................................................ 206
Idler Pulley .................................................................................................... 208
Carriage Wheel .............................................................................................. 209
Seal Belt ........................................................................................................ 210
Split Rollers ................................................................................................... 213
Flex Cable ...................................................................................................... 215
Electric Chassis ............................................................................................. 218
Motor Drive Replacement (ABB ACS-100) ................................................. 222
Drive Motor Controller (Fincor and Lovejoy) ............................................... 223
Pressure Switch ............................................................................................. 225
Encoder .......................................................................................................... 226
Replacement Parts List .................................................................................. 227
Replacement Parts for the ASPC ................................................................... 230
101764-003 Replacement Procedures 203


Drive Motor Belt

Use these procedures to replace the drive motor belt. Refer to Figure 10-1 and
Figure 10-2 on page 205.
1. Turn off the power to the drive motor.
2. Loosen the tension on the drive motor belt by completing the following:
a. Loosen the four drive motor mount adjustment bolts.
b. Slide the assembly towards the drive shaft and take the belt off of the motor
pulley.
Drive Motor
Gear Reducer
Assembly
Adjustment Adjustment
Bolts
Figure 10-1 Drive Motor Belt

3. Disengage the air clutch by using the head separation switch so that the two
drive shafts can move independently.
4. Remove the two metric Allen screws that hold the collar to the shaft.
5. Remove the three SAE bolts on the mating collar.
6. Remove the collar which exposes a two–inch gap between the upper and lower
drive shafts to allow removal of the drive motor belt.
7. Replace the drive motor belt.
8. Adjust the tension and tighten the drive position adjustment locks.
204 Replacement Procedures 101764-003


Metric
Allen Screws
Upper Drive Shaft Mating

Slot Key Collar
Set Screw
(for Reference)
Clutch
Assembly
Lower Collar
Lower Drive Shaft
Figure 10-2 Clutch Assembly Details


Carriage Drive Belt

Use these procedures to replace the carriage drive belt. Once this procedure is
completed, perform a scan direction alignment to make certain that the sensor heads
are tracking each other. Refer to Figure 10-3 on page 207. The carriage alignment
in the drive direction may need to be reset. To check the alignment, complete the
“Scan Direction Alignment” on page 54.
Note: When replacing a failed belt, it is required that both top and bottom
belts be replaced as a matched set. Replacing both belts at the
same time maintains sensor alignment by eliminating variation
between belts due to wear. In an emergency situation, it is
acceptable to defer replacement of the second belt until the first
scheduled maintenance shutdown.
Belt Length = 2 × center - to - center + 8.75 in
Equation 10-1 Carriage Drive Belt Equation

1. Disengage the air clutch so that the heads can be separated.
3. Move the head carriage with the defective belt to the Smart Platform idler end
column.
4. Release the belt tension by loosening the idler pulley at the Smart Platform idler
end column.
5. Remove the end of the drive belt which is attached to the idler end of the carriage
assembly.
6. Attach the new belt with strong tape to one end of the old belt which was
removed in the previous step.
7. Go to the drive end of the Smart Platform and pull the new drive belt through
the structure.
8. Attach the other end of the new belt to the idler end of the carriage assembly.
9. Move the head carriage to the Smart Platform drive end, and at the same time,
pull the new belt along with it.
10. Disconnect the two belts attached in Step 6 and discard the old belt.
11. Cut the new belt to a length such that when it is attached to the carriage assembly,
the tension can be adequately adjusted using the idler tension adjustments.
12. Attach the remaining loose end of the new belt to the drive end of the carriage
assembly.
13. Move the head with the new drive belt, center them, and engage the air clutch.
14. Tighten the new belt to 125 + 25 pounds.


Head
Separation
Switch
New Belt
Old Belt
Tape
Drive End
Figure 10-3 Carriage Drive Belt


Idler Pulley
Use these procedures to replace the idler pulley. Refer to Figure 10-4.
Exercise care when working with toothed belt and

toothed gear equipment. Do not wear ties or loose
clothing while working near equipment.
1. Turn Off the power to the drive motor.

2. Loosen the idler tension adjustment locks and loosen idler pulley.
3. Remove the shaft on the pulley shaft that secures the pulley and lift the pulley
off from the shaft.
4. Replace pulley assembly.
5. Adjust tension by adjusting the idler tension adjustments.
6. Perform the Scanning Direction Alignment Procedure in Chapter 3, page 54.
Side View
Pulley Shaft
Drive Pulley
Top View
Pulley Tension Drive Belt

Adjustment Locks
Pulley Tension
Adjustments
Figure 10-4 Idler Pulley


Carriage Wheel
Use these procedures to replace the carriage wheel. Refer to Figure 10-5.
1. Move carriage assembly to either the idler end or the drive end of the platform
depending upon which wheels need replaced.
2. Remove both of the bolts which are holding the carriage wheel to the assembly.
3. Remove the wheel from the axle.
4. Replace the wheel and secure the two bolts which attaches the wheel to the
carriage assembly.
Carriage Carriage Wheel
Bolt
Way Bar
Figure 10-5 Carriage Wheel


Seal Belt
Use these procedures to replace the Seal Belt. Refer to Figure 10-6, Figure 10-7
on page 211, and Figure 10-8 on page 212.
The Smart Platform design allows replacement of this

item while the customer’s process is running. Exercise
caution to ensure that the seal belt is kept clear of the
process while being removed and replaced.
1. Loosen the seal belt clamp at the drive end.
Seal Belt Clamp

Adjustments
Seal Belt Clamp
Seal Belt
Figure 10-6 Seal Belt Clamp

2. Loosen the seal belt clamp at the Smart Platform idler end.
3. Pull the seal belt through the Smart Platform idler end.
4. Jog sensor heads to the Smart Platform idler end.
5. Turn off power to the drive motor.


6. Thread the seal belt into position at the idler end under the seal belt roller and
guide through the carriage assembly.
Note: It is extremely important to note that the seal belt should be centered
between the extrusions otherwise the belt may rub the side of the
extrusions while the sensor heads are scanning. This condition
could result in unsteady scanning and premature wear of the seal
belt.
Carriage
Carriage Seal Belt Rollers

Seal Belt
Figure 10-7 Seal Belt

7. Secure belt at the drive end of the carriage with tape.
8. Turn on the power to the Smart Platform long enough to jog the sensor heads
to the drive end platform while maintaining enough tension to ensure that the
seal belt does not contact the customer process.
9. Secure the belt at the drive end by threading through the seal belt clamp and
tightening the clamp.
10. Pull seal belt from idler end of the platform to remove any slack in the seal belt.
11. Turn on power to the Smart Platform long enough to jog sensor heads to the
idler end carefully taking up slack in the seal belt.
12. Adjust tension such that the seal belt lays flat in the tray without any deflections
in the seal belt roller assembly.


Carriage Seal
Belt Rollers

Adjusted Too
Tightly
Extrusions
Seal Tension
Adjusted
Unevenly
Seal Belt
Seal Tension
Adjusted
Properly Seal Belt


Split Rollers
Use these procedures to replace one of the split rollers. Refer to Figure 10-9,
Figure 10-10 on page 214, and Figure 10-11 on page 214.

caution to ensure that the seal belt is kept clear of the
1. Jog the sensor heads to the end column that provides access to the split roller
that needs replaced.
3. Loosen the seal belt clamp and relieve tension from the split roller assembly.
Seal Belt Clamp

Adjustments
Seal Belt Clamp
Seal Belt
Figure 10-9 Seal Belt Tension Adjustments

4. Remove the bolt securing the damaged split roller assembly.


Drive Timing Add thread–locking

Belt compound In Threads
Retaining
Bolt
Figure 10-10 Split Roller Assembly

5. Remove the split roller.
6. Install the new split roller.
7. Add thread–locking compound to the threads of the bolt that secures the split
roller. Reinstall it.
8. Pull the seal belt through the seal belt clamp to remove any slack in the seal belt.
9. Adjust tension such that the seal belt lays flat in the tray without any deflections
in the seal belt roller assembly.

Adjusted Too
Tightly Carriage Seal
Belt Rollers
Extrusions
Seal Tension
Adjusted
Unevenly
Seal Belt
Seal Tension
Adjusted
Properly Seal Belt


Flex Cable
Complete the following steps to replace the cable suspension. Refer to
Figure 10-12 and Figure 10-13 on page 216.

caution to ensure that the flex cable is kept clear of the
Flex Cable Length = center - to - center + 120 in.
Equation 10-3 Flex Cable Length Equation

1. Put the platform in local mode and jog the head to the idler end column.
2. Pull out the carriage PC board, and disconnect the signal and power cable
connectors. At the carriage end only, cut off the connectors from the signal and
power cables.
12 Volt Aux Power Cable Aux Signal High Voltage Electrometer

Auxiliary
Power Supply Connecter Cable Connector Power Supply Assembly
Cable Line
J21
J12
J1 J2
Power Cable Electric Sensor Cable

Connectors Chassis
Cable Ribbon Signal Cable Connector
Carrier Cable Connecter
Upper Assembly Top View
Figure 10-12 Carriage Assembly (Top View)
Note: It may become necessary to cut the utility lines on the manifold at
the Smart Platform idler end. The utility line is long enough to take
up the slack. However, this should not be done too many times.
Make sure the ribbon cable connectors are flat. This will make
removal easier.


3. Disconnect power and signal cables from the idler end column PC board.
4. Jog the head to the drive end.
5. At the drive end, remove cable carrier mounting bracket.
6. Roll cable carrier back and pull power and signal cables from carriage.
7. At the idler end column, remove cable carrier retaining bolt.
8. Pull cable carrier out just enough so that it lays flat at the drive end.
9. At the drive end, with both cables out of the carriage, tape the old cable to the
new cable using a high–strength tape. For example, use strapping or shipping
tape.
Old
New Cable
Cable
8”
To Cable
Carrier
20” Tape
Figure 10-13 Cable Suspension

10. While one person at the drive end guides the new cable through the cable carrier,
another person at the idler end column pulls the new cable through the platform.
Once the cable is all the way through, leave enough excess cable at the idler
end column to allow for a cable dress back into the idler end PC board.
Keep the cable carrier, ribbon cables, and utility lines clean. Dust and dirt will
cause premature wear of the cables.
Note: Replacement of the complete assembly, ribbon cables, or utility lines

can be accomplished at this time. If replacing the ribbon cable
assembly, measure the length of cable exposed at each end and
terminate new cable at the same length.
11. At the drive end, leave 60 inches of excess cable from the end of the cable carrier
and cut the cable.
12. Terminate the signal cable according to Engineering Drawings 121974-003 and
121974-004.
Note: Do not reuse signal cable connectors. They must be replaced each
time a new signal cable is installed.
13. Terminate power cable according to Engineering Drawings 121974-003, and

121974-004.
14. Feed cables back at the same time through the trough leading to the carriage
and reinstall the cable carrier mounting bracket.


15. At the idler end column, reinstall the cable carrier retaining bolt and cut the
new power cable to the length needed to dress into the end column PC board.
Install the connector according to Engineering Drawings 121974-003 and
121974-004.
16. Reconnect the power and signal cables to the idler end column PC board.
17. Jog the head to the idler end column, pull out the carriage PC board and
reconnect the power and signal cables.
18. Push the carriage PC board back into place.


Electric Chassis
There have been several reported occurrences of the MP

power flex cable being plugged in wrong. A typical error
puts 120 VAC where the ± 15 VDC is supposed to be. If
the system is powered up with the power cable plugged
in wrong, catastrophic failure of sensors is likely.
Electric Chassis Replacement Procedure
Complete the following procedure to replace the electric chassis in the upper or
lower carriage. Refer to Figure 10-14 on page 219.
1. Jog sensor heads to the Smart Platform idler end.
2. Turn Off power to the Smart Platform.
3. Remove the carriage end cover, then pull out the electric chassis.
4. Remove the cable connectors for the sensor interconnection.
5. Remove the ribbon cable connectors for the cable suspension from the carriage
electric chassis.
6. Replace ribbon cable connectors for the cable suspension.
7. Replace the cable connectors for the sensor interconnection.
8. Slide the replacement electric chassis in place.
9. Replace the carriage end cover.
10. Turn On power to the Smart Platform.


Second Cable Second Cable Second Cable

IR Lamp Carrier Power Carrier Signal Carrier Sensor High Voltage Electrometer
Filament Transformer Cable Connector CableConnector Connector Power Supply Assembly
J13 J14 J15 J16 J17 J18 J19 J20
J21
J12
J1 J2
J5 J6 J7 J8 J9 J10 J11
J3 J4
First Cable Carrier First Cable Carrier First Cable Carrier
Power Cable Signal Cable Sensor Cable
Connectors Connector Connectors
Upper Assembly Top

NOTE: Static Box is not shown View
Idler End
View
Power Cable
Connectors
J13 J14 J15 J16 J17 J18 J19 J20
J21 J12
J1 J2
J5 J6 J7 J8 J9 J10 J11
J3 J4
Signal Cable
Connector
Lower Assembly Top

View
Figure 10-14 Carriage Assembly


Flex Power Cable Retrofit Kit

The Flex Power Cable Retrofit Kit (Part Number GK-130618-001), significantly
mistake proofs against plugging the power cable connectors in wrong.
The kit includes the following:
• Two 9-pin connectors (Part Number 101929-609)
• Two keying caps (Part Number 101929-901)
• Drawing Number DI-130618-000
One kit is enough to do one scanner (top and bottom) or two reflection scanners.
The second flex cable (used for ash only) does not use two connectors so it does
not need any rework.
Note: Changing the connectors will not prevent damage if the connectors
are not installed on the cable correctly. The verification procedures
on the instruction drawing are still required when replacing cables.
However, once the cable is correctly made, use of this kit should
prevent the connectors from being plugged in wrong.
Flex Cable Replacements

The correct procedure requires you to verify that the cables are correctly installed
before repowering any sensors. There are two relatively simple ways to do this:
• After plugging the system back together, before repowering the frame, use two
diagnostic cards and do continuity checks between the end column diagnostic
plug and the carriage diagnostic plug.
• Unplug all of the sensor cables, electrometer, chamber supply, and IR
transformer so you can power up the frame without danger of destroying your
sensors. Check the supply voltages on the diagnostic plug (s) at the carriage
before plugging anything back together. Again, refer to your test card inserts.
Doing both checks is recommended to make sure all of the wires are in the right
place and there are not any catastrophic failures.
Figure 10-15 on page 221 shows the proper cable dress in a Smart Platform 1200.
Note that the longer side of the power cable plugs into the back connector (towards
the drive end of the carriage board). The short side of the power cable plugs into
the front connector (closer to the “idler” end). That is done to help from the cable
loop so you can slide the carriage board assembly out.


Unfortunately, when the carriage board is pulled all the

way out, the cable looks backwards if you forget about
that loop. If you do not remember the loop, and plug the
cable in the way it probably looks like you should, you
just did it wrong.
MPII/SP1200 CARRIAGE ASSEMBLY SIDE VIEW Flex

Track
IDLER END
Cable Loop
Diagnostic Plug short long Service

Carriage Board Loop DRIVE
Carrage Sled END
Figure 10-15 Side View of Proper Cable Dress for SP1200


Motor Drive Replacement (ABB ACS-100)

Complete the following procedure to replace the Motor Drive. Refer to
Figure 10-16.

1. Turn Off power to the Motor Drive sled.

2. Pull out the Motor Drive sled.
3. Disconnect the three cables from the Motor Drive sled.
4. Remove the old motor drive sled and replace with the new one.
5. Reconnect the cables to the Motor Drive sled.
6. Return Motor Drive sled to its position in the drive end column.
7. Turn On power to the controller and complete the Motor Controller Setup
procedure. See “Motor Drive Setup (ABB ACS-100)” on page 72.
Note: If the motor happens to run backwards, swap the wires in JDRV-1
and JDRV-3.
8. Execute the standard frame tuning procedure (ft) in the software.
Motor Drive
Figure 10-16 SP1200 Motor Drive Assembly


Drive Motor Controller (Fincor and Lovejoy)

Complete the following procedure to replace the Drive Motor Controller. Refer to
Figure 10-17 on page 224.

1. Turn Off power to the drive motor controller.

2. Slide out the motor controller shelf.
3. Remove the cover for the drive motor controller.
4. Disconnect wiring for the drive motor controller.
Note: Be sure to note the wiring configuration and mark cabling if

necessary. This will assure that the new controller matches the old
controller. Failure to do so can result in damage to the motor and/
or motor controller.
5. Remove motor controller.

6. Install new drive motor controller and make all wiring connections.
7. Turn On power to the controller and complete the Motor Controller Setup
procedure. If the platform scans in the reverse direction, reverse the wires on
terminals V and W on the motor controller.
8. Replace cover to the motor controller.
Replace the motor controller shelf.


Mounting Screws
Motor Controller
Mounting Sled
Smart Platform
Figure 10-17 Drive Motor Controller


Pressure Switch
Complete the following procedures to replace the pressure switch. Refer to
Figure 10-18.
1. At the drive end, remove the bolt that holds the bracket on which the solenoid
and pressure switch rest.
2. After the bracket has been removed, detach the two wires from the top of the
the pressure switch.
3. Unscrew the pressure switch.
4. Install the new pressure switch and make the wiring connections.
5. Reattach the bracket to the drive end of the Smart Platform.
Solenoid Pressure
Switch
Smart Platform
Figure 10-18 Pressure Switch


Encoder
Complete the following procedure to replace the Encoder. Refer to Figure 10-19
on page 229.
1. Unplug the D connector from the encoder cable.
2. Remove the four screws which are holding the encoder to the metal plate.
Lift the encoder from the plate.


Replacement Parts List

Refer to:
• Table 10-1
• Figure 10-19 on page 229
Table 10-1
Key Smart Platform Part
Letter Replacement Parts List Numbers
END COLUMN, DRIVE-SIDE
Drive Motor Belt (54 T) 015125-008
G Pillow Block (3 req’d) 011756-106
B Drive Pulley (2 req’d) 121849-001
Key (4 req’d) 046102-013
Ball Bearing Flange 011230-107
F Gear Motor, incl. reducer 100456-003
E Pressure Switch (15 A) SC0001-001
D Air Solenoid Valve (1/8”) MW0018-001
A Encoder 019775-004
END COLUMN, IDLER-SIDE
Bushing (2 req’d) 121802-001
Pulley Assembly (2 req’d) 121850-002
Manifold 127202-001
MOTOR DRIVE
C SP1200 Motor Drive Assembly including 126620-005
MDPanel and Filter
Motor Drive Subassembly (Remote Junction 133853-001
Box only)
Motor Controller Choke Assy. (Remote 086277-001
Junction Box only)
240 VAC Fan 102258-001
CONTROL PANEL
Control Panel (Keypad) 100472-012
Control Panel Interface Board (Serial) 086351-003
DOOR HARDWARE
LH Hinge 100497-002
RH Hinge 100497-001
Latch, adjustable 100498-001
(continued on next page)


Table 10-1 (continued)

Letter Replacement Parts List Numbers
SMART PLATFORM
Limit switches, std. 100524-001
Adjustable limit switch kit 121994-002
Seal Belt, polyester 100524-001
CARRIAGE FRAME
Carriage Light Assy. 084910-001
Cover, way adjuster 121966-001
CARRIAGE, INTERNAL
Cable Carrier, Divided 100490-005
Hose, Dual flat 101497-001
Signal Cable, flat (for divided cable carrier) 101575-037
Power Cable, flat flex 100983-003
Connector (37 Pos, receptacle) 101403-037
Connector (37 Pos, plug) 101403-137
Connector (37 Pos) Screw Retainer Kit 101403-901
Stabilizer (37 Pos) 101405-837
Cable Carrier, Undivided 100490-001
Signal Cable, Flat, for undivided cable 100577-037
carrier
Drive Belt 100446-001
Wheel assy. 121975-001
Wheel assy., expansion 121975-002
Carriage Connection board 085218-001
PURGE BLOWER
High Capacity Purge Blower 101495-006
Purge Blower Assembly without Cabinet and 123595-008
with High Capacity Purge Blower


D E
F
A
B
Detail - Drive Motor Mechanism
Figure 10-19 Drive End Column Parts


Replacement Parts for the ASPC

Refer to:
• Table 10-2
Table 10-2
Letters Electronics Numbers
A ECS Board 086329-103
B SMI (located on the ECF and ECS boards) 086339-101
(IR CoatWeight and Aseptic Only) 086339-002
C ECF 086348-001
D* MPRC 086349-102
or
086444-101
E BRAM (located on MPRC board) 086318-001
F ECPSR 086370-001
G Heat Exchanger 101376-001
H Fan, 24 VDC 128950-001
I OSPS2 086363-002
J EC24V 086362-001
K HAM 086369-001
J1 12 VDC Plug-on for EC24V 101554-912
J2 Fuse, Plug-on for EC24V 101560-003
(3 amp) and HAM
M AC to DC Converter, 101554-300
300 VDC
K1 48 VDC Plug-in for HAM 101554-148
L 5 Amp Fuse 018252-008
N ECC 086387-001
* When replacing an 086349-002 with an 086444-001, a kit should be
ordered (086444-101). This kit includes the 086444-001 MPRC board
plus instructions for loading the required software upgrade from ABBIE.


Note: Modules attached to printed wiring boards must be ordered

separately. Modules are not supplied as part of printed wiring board
assemblies. Always order the exact part number which is on the
defective part. If a newer dash number is available, the parts
department will supply it. Some systems will have dash numbers
newer than the above list.


A or N A
Figure 10-20 SP Electronics Cabinet (086345-004 Backplane Version)


Figure 10-21 SP Electronics Cabinet (086345-003 Backplane Version)


ERROR
RUN
B B
RXA
RXB
RXC
RXD
RXE
RXF
E
RTSA RTSA
ERROR ERROR
RUN SMI RUN SMI
RTSB Board RTSB Board
START MODE
EXTEN
DIAG
SHORT
DIAG
STOP/
DEBUG
ECS ECF
BRAM
Board
RX HOST
RESET
MPRC
Figure 10-22 Location of SMI and BRAM Boards


OPTIPAK
GLOSS 1
GLOSS 2
Lights
DISABLE I J, J1, J2 K, K1, J2

DC IN
Lights M
Side View +12V OUT

-12V OUT
Lights
Idler End
Figure 10-23 Location of OSPS2 and EC24V

Blank Page

11
Troubleshooting
This chapter describes basic troubleshooting that can be done using the LED in the
Smart Platform electronics cabinet and through console messages that are displayed
at startup.
Section............................................................................................... Page
Alarm Messages ............................................................................................ 238
LED Interpretation ........................................................................................ 242
Power Down and DC Power Analysis ........................................................... 246
Diagnostic Card Operation ............................................................................ 249
Troubleshooting Start-Up Messages ............................................................. 261
101764-003 Troubleshooting 237


Alarm Messages
Alarm messages are associated with each of the Service Workstation Health
Reports. The alarm messages below may appear on the Report pages for Electronics
Health and Frame Health. Alarms from other health reports are explained in
manuals describing operation and maintenance for those features.
Messages which appear in the ‘pe’ log are not explained here. These appear only
in manuals targeted for advanced troubleshooting.
Note: Most actions suggested below assume the hardware path leading
back into the software is functioning. This includes the ECF board,
the SMI daughter board, and the MPRC board. These are also
candidates for replacement during any troubleshooting.
Electronics Health Report

End Column Power Temp Out of Limits
The temperature of the power supply converter board, located in the end column
card cage, has exceeded the maintenance limit of 50˚C. If it reaches 65˚C, the Smart
Platform will power down.
A Board Temperature Is Out of Limits
The temperature of one of the microcontroller ECS boards or the MPRC board,
located in the end column card cage, has exceeded the maintenance limit of 50˚C.
If it reaches 65˚C, the Smart Platform will power down. If the ECF is the one
affected, then the limits are 59˚C and 69˚C.
Chiller Flow Out of Limits
The digital input indicating the state of flow (on/off) from the chiller flow unit is
showing no flow. The chiller flow unit provides cooling for both the end column
card cage as well as any IR Moisture sensor mounted on the scanner. If a second
chiller unit does NOT exist, then the alarm for the second unit can be disabled by
using the dim utility to invert the input bit.
238 Troubleshooting 101764-003


Voltage Level Out of Limits

Various board voltages on each microcontroller are derived from the + and - 15 volt
power supply board voltages. The range of each voltage is as follows:
low high
AnalogPosVolt01_ai 14.6 15.4 *
AnalogNegVolt01_ai -15.4 -14.6 *
DigitalVolt01_ai (ECF) 4.9 5.1 *
ThermRefVolt01_ai 4.44 4.56
A2DRefVolt01_ai 4.45 4.55
A2D Test Volts (ECF) 4.85 5.15 **
* Voltage is derived from the ECPSR power supply board.
** A feedback test signal from the ECF A2D converter.
Communications Loss For Frame Micro
Beta Micro
IR Micro
Caliper Micro
Optipak Micro
Gloss Micro
Ash Micro
General Micro
HDLC communication to the specified sensor/frame microcontroller has been lost.
Usually a reconnect results in recovery without any loss of performance. If multiple
microcontrollers are disconnected, it could mean a defective MPRC board.
Persistent disconnects of a single microcontroller may mean that the board is
defective.
There are two HDLC comm lines used. The assignments are as follows:
LINE 1 - ECF, Basis Weight, Gloss, Ash
LINE 2 - IR Moisture, Caliper, OptiPak, General/Color
Undefined Alarm
Some alarm condition has occurred for which there is no display text. Note the
associated code and call the Support Line for assistance.


Frame Health Report

Motor Stopped by Obstacle
There has been no detected motion along the current trajectory causing an excessive
position error. Possible areas of investigation are the motor controller, a mechanical
failure of the drive train, incorrect setup of the motor controller, or vminTune turned
off with activeVmin set too low.
Head Position Verify Test - Timeout
The ‘Self Test’ push button on the Frame Control Panel has been pushed with the
frame in LOCAL (hand) and the sequence of resynchronizing and positioning to
off-sheet has not been able to complete. Check for defective motor controller,
encoder, ECF board, and home limit switch. The red LED on the panel push button
should be flashing.
Head Position Verify Outside Limits
The ‘Self Test’ results are not within acceptable limits. The resultant off-sheet
position reached was not within 20 encoder counts of the original position. The red
LED on the push button will remain flashing. Possible problem with the encoder
slipping, or a bad ECF board.
Head Resynchronize - Timeout
Encoder synchronization has failed to take place after being initiated. Could be a
problem with the encoder or ECF board.
Head Speed Inconsistency
Caused when the system response to the servo commands results in one of the
following three conditions: (1) vmin tuning has been aborted, (2) there is an
excessive ddc error, or (3) the servo has timed out. First check for a mistuned servo
setup, including the motor controller itself. Could also have hardware problems
with MPRC and ECF boards.
Beam Air Flow Off
There currently is no air flow switch monitoring the beam air flow. If this alarm
appears, it means that the bit in the ECF board is being seen as set. Correct by using
the dim utility to invert the bit.
Power Shelf Temperature Out of Limits
The temperature of the power supply shelf has exceeded the maintenance limit of
50˚C. If it reaches 65˚C, the SP will power down.
Motor Controller Temp Out of Limits
Temperature feedback from the motor controller assembly has exceeded the
maintenance limit of 50˚C. If it reaches 65˚C, the SP will power down.


AI Slope and Offset Calc Failed

Failure of the ECF board to set up properly for processing the head position signal.
Could be a bad ECF board.
Undefined Alarm
Some alarm condition has occurred for which there is no display text. Note the
associated code and call the Support Line for assistance.


LED Interpretation
Basic troubleshooting that can be done using the LEDs in the Smart Platform
electronics cabinet.
Power Supply LEDs
The power supply is in the Smart Platform electronics cabinet. Use the following
table to assist you in troubleshooting the Smart Platform electronics. Refer to
Table 11-1 and Figure 10-21 on page 233.
Table 11-1 Interpretation of LEDs
LEDs DESCRIPTION
DC IN This LED refers to the 24 VDC power supply for the
on ECPSR Smart Platform electronics cabinet.
When this LED is lit, the power supply is on, but may
not be within acceptable tolerance.
DISABLE This LED refers to the 24 VDC power supply for the
Smart Platform Electronics cabinet.
When this LED is lit, 24 volts is not within acceptable
tolerance and the +5V and ± 15V power supply has
been shut down.
+15 V These LEDs refer to the presence of their respective

-15 V voltages within the Smart Platform electronics
+5 V cabinet.
When these LEDs are lit, the respective voltages are
within acceptable tolerances.


ECF and ECS LEDs

These LEDs are located on the ECF and ECS boards in the Smart Platform
electronics cabinet. Use the following table to assist you in troubleshooting. Refer
to Table 11-2 and Figure 10-21 on page 233.
Table 11-2 ECF/ECS LED Interpretation
LEDs DESCRIPTION
RTSA (green) The LED flashes when HDLC Port A has set its request
to send and is attempting to transmit data.
The intensity of the flashing depends on how much data
is being transmitted.
If the LED stays on after reset, replace the SMI.
If the LED is flashing check the service console.
are normal.
If there are no LEDs lit, check to make certain there is
power to the board.
RUN (green) This LED is driven by the data strobe and indicates the
level of 68332 external bus activity.
RTSB (green) This LED is not currently being used and should be off.


MPRC LEDs
These LEDs are located on the MPRC board in the Smart Platform electronics
cabinet. Use the following table to assist you in troubleshooting. Refer to
Table 11-3 and Figure 10-21 on page 233.
LEDs DESCRIPTION
ERROR (red) This LED indicates status of local diagnostics; it is
under software control on a reset.
If the LED stays on after reset, replace the SMI.
If the LED is off and the RUN light is flashing,
conditions are normal.
If there are no LEDs lit, check to make certain there
is power to the board.
RUN (green) This LED is driven by the data strobe and indicates
RX TERMINAL When the LED is lit (flashing), there is a physical
When the LED is not lit (flashing), the physical
connection to the terminal is broken.
RX HOST When the LED is lit (flashing), there is a physical
When the LED is not lit (flashing), the physical
connection to the terminal is broken.



LEDs Description
are normal.
to the board.
RUN (green) This LED is driven by “Transfer in Progress” and indicates
NET TX_B (green) When lit, the Ethernet port on J2 (Port B) is transmitting
data.
NET TX_A (green) When lit, the Ethernet port on the ASPC Host Connector
(Port A) is transmitting data.
RTS 0 (green) HDLC Port 0 is transmitting to the sensor microcontrollers.
RTS 1 (green) When lit, HDLC Port 1 is transmitting to the sensor
microcontrollers.
Platform).
Platform).
(green) connection to the terminal.
terminal is broken.
RX HOST (green) When the LED is lit or flashing, there is a physical
is broken.


Power Down and DC Power Analysis

If the system resets because of a power down condition, the cause can be determined
by printing out an array of temperature and DC power data through a shell script.
The temperature values within the system are monitored and checked against safety
limits. When a safety limit is violated, the system will issue an alarm message and
record, in a buffer, the current values of all of the temperatures. When the power
down limit is exceeded, the temperature data is again read into the buffer. This
buffer is stored in the /ss01 BRAM disk area so that it is available at the next startup.
Upon startup, the file is read in, where it is available for display using the shell script
command. While several variables may have exceeded their safety alarm limit, the
file shows the snapshot of the data at the moment the first power down event occurs.
Figure 11-1 on page 247 shows the subsystem temperature report. The information
in italics is not printed, but is shown here to help decipher the somewhat cryptic
labels.
Table 11-5 shows the associated alarm limits for each of the variables.
Table 11-5 Alarm Limits for Each Variable
Safety limit Power Down
Temperature Categories (°C) (°C)
All board and platform temperatures 50 65
Basis Weight Temperatures with gap 100 125
Basis Weight Temperatures without gap 130 148
Ash Temperatures with gap 100 125
Ash Temperatures without gap 90 125
Caliper Temperatures 130 148
Figure 11-2 on page 248 shows the historical trend of each microcontroller’s DC
voltages. It is a rotating buffer of the last 20 updates. A snapshot update of all the
DC power on the board is made each time a new high or low value for any of the
DC levels is detected. This check is made every minute. This data can be viewed
periodically by executing the shell script. Reviewing this data is useful in
determining trends in power supply drift.
To print out both reports, at the AVOS shell ($$ prompt), type:
. /ss01/clm/pwrDnInf
The system displays, on the screen and printer (if available), the Power Down report
including the microcontroller temperature and the DC power history for each
microcontroller in the system.


UCONTROLLER SUBSYSTEM TEMPERATURES: 12-21-1991 12:57:14
brdTemp[ 0 ]: 33.90 (frame)

brdTemp[ 1 ]: 28.99 (Basis Weight)
brdTemp[ 2 ]: 29.55 (IRMoisture)
brdTemp[ 3 ]: 0.00 (Caliper)
brdTemp[ 4 ]: 30.15 (OptiPak)
brdTemp[ 5 ]: 0.00 (Gloss)
brdTemp[ 6 ]: 30.75 (Ash)
brdTemp[ 7 ]: 35.87 (General)
ecespTemp: 5.00 (End Column Temperature)
beamAirFlowAlm:(BOOL)1 ALARM
chillFlowAlmA:(BOOL)1 ALARM
chillFlowAlmB:(BOOL)1 ALARM
spare:(BOOL)0 UNUSED
ash_sct 0.00 (with gap source CAP temperature)
ash_dct 0.00 (with gap detector CAP
temperature)
ash_sht 44.52 (without gap head CAP
temperature)
beta_sct 0.00 (with gap source CAP temperature)
beta_dct 0.00 (with gap detector CAP
temperature)
beta_sgt 53.91 (without gap source gap
temperature)
beta_dgt 53.87 (without gap detector CAP
temperature)
beta_sht 54.90 (without gap source column
temperature)
beta_dht 55.81 (without gap detector column
temperature)
caliper_probtemp: 0.00
(Text in italics is shown for clarification and does not appear on the actual report.)
Figure 11-1 Subsystem Temperature Report


Date Temp Vapos Vaneg Vref Vtref Vdig

12-12-1991 11:19:56 33.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:20:58 33.40 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:25:01 33.90 15.02 -14.96 5.00 5.00 5.00
12-12-1991 11:28:03 33.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 11:36:07 33.90 15.10 -14.92 5.00 5.00 5.00
12-12-1991 11:52:13 33.40 15.10 -14.96 5.00 5.00 4.96
12-12-1991 13:56:14 32.90 15.10 -14.96 5.00 5.00 5.00
12-12-1991 14:32:40 33.40 15.10 -14.96 5.00 5.00 5.04
12-12-1991 14:40:48 33.40 15.10 -14.96 5.00 5.04 5.00
12-12-1991 16:31:46 33.40 15.10 -14.96 4.96 4.96 5.00
12-13-1991 08:31:33 32.90 15.10 -14.96 5.00 5.00 5.00
12-13-1991 08:32:35 33.40 15.10 -14.96 5.00 5.00 5.00
12-13-1991 08:34:38 33.40 15.10 -14.96 5.00 4.96 5.00
12-13-1991 08:35:39 33.40 15.10 -14.92 5.00 5.00 5.00
12-13-1991 08:36:40 33.40 15.02 -14.92 5.00 5.00 5.00
12-13-1991 08:45:47 33.40 15.10 -14.96 5.00 5.00 4.96
12-13-1991 08:47:49 33.90 15.10 -14.96 5.00 5.00 4.96
12-13-1991 09:20:07 33.40 15.02 -14.96 5.00 4.92 5.00
12-13-1991 10:06:07 33.40 15.10 -14.96 4.96 5.00 5.00
12-13-1991 11:02:43 33.90 15.10 -14.96 5.00 5.04
Figure 11-2 Historical Trend Report for Microcontroller DC Voltages

Note the following definitions for Figure 11-2:
Vref - is the A to D signal
Vtref - is the thermistor reference
Vdig - is the logic signal for the ECF board only


Diagnostic Card Operation

The Smart Platform diagnostic card (See “Diagnostic Cards” on page 252.) slides
into a plug-in unit that provides a source for easy checks for voltages and signals.
The Smart Processing Center and the Sensor Electrical Interconnect board (SEI)
have diagnostic connectors with which the plug-in unit connects.
Test Card Kit
Test Board Kit
Smart Processing Center

Smart Platform
Top Signal
J1 TOP
SIGNAL
DIAGNOSTICS
J2
TOP SIGNAL
J3
J4
TOP POWER
DVM
Figure 11-3 Test Board Hookup


Diagnostics Performed at the Sensor

Reference Figure 11-4 on page 251 and Figure 11-5 on page 251.
The Sensor Electrical Interconnect board (SEI) is a printed circuit board used in
basis weight and ash source and detector modules. The SEI distributes signals and
power to the proper connectors. It contains the sensor diagnostics plug which allows
external access to internal signals for troubleshooting. Electrical ORUs have cables
or plugs that interface to this board. The air solenoids, PTC module, and the CAP
thermistor make connections to this board in the source module. The Gap sensor
printed circuit board, ELHV board, PTC power and CAP thermistor all plug into
this board in the detector module.
The diagnostic access port is the cover located in the sensor module housing
allowing external access to the diagnostic connector located on the SEI. Head
package sheet guides may have to be removed to gain access to this panel.
The sensor diagnostic plug is a 37-pin connector designed to accept the diagnostic
tool typically used to troubleshoot Smart Platforms and Smart Processing Centers.
This diagnostic access is important for STLK-11 and STLP-3 sensors since it is
impossible to gain internal access to powered up assemblies. Side plate access to
internal assemblies does not exist. Sensor power is automatically disconnected
through the connector if internal access is required.
There are three Light Emitting Diodes (LEDs) on the SEI board. The LEDs indicate
the shutter status, internal check sample and PTC heater assembly on the source
module. On the detector module the status of the PTC heater assembly is indicated,
the other two lights are not used. They can be viewed through acrylic windows at
the end of the sensor housing. Removal of the sheet guides may be necessary for
clear viewing of the LEDs.


CAP
Diagnostic Plug
Electrical
Interconnect
Board Diagnostic
Access
PTC Heater Port
Module Diagnostic
LEDs
Air Solenoid
Figure 11-4 Basis Weight Source Module
ELHV
Board
Electrical
Interconnect
Board
Diagnostic
LEDs
Diagnostic
Access Port
Diagnostic
Plug
Figure 11-5 Basis Weight Detector Module


Diagnostic Cards
The pictured diagnostic cards may not represent

those for your system.
The Top Power card is to be used for diagnostics performed at the sensor only. Refer
to Figure 11-6 on page 253.


1 POWER COMMON
SYSTEM AccuRay®
-12 VDC
20 LO 19
IR
2 HV TEST CARRIAGE 120 VAC
ONLY HI 37
21 +12 VDC
SYSTEM CALIPER
PRESSURE LO 36
22 RETURN HEATED
AIR WIPE LO 35
GLOSS LAMP
23 POWER 120 VAC
HI 34
24 RETURN ASH
HEATER
OPTIPAK LAMP LO 33
25 POWER 120 VAC

HI 32
28 -15 VDC
BW
HEATER LO 31
27 SIGNAL SYSTEM
COMMON CALIPER
HEAD LIFT
SOLENOID LO 30
28 +15 VDC
SMART PLATFORM
TOP POWER
086086-052, SIDE 1, REV A
Figure 11-6 Sample Diagnostic Card: Top Power

The Bottom Power card is to be used for diagnostics performed at the sensor only.
Refer to Figure 11-7 on page 254.


1 POWER COMMON
AccuRay®
20 -12 VDC 19
SYSTEM 37
21 +12 VDC
BW SHUTTER
LO 36
22 SHUTTER CALIPER HEATER/

VACUUM/PURGE
LO 35
ASH
23 FLAG 120 VAC

HI 34
24 RETURN ASH
HEATER
GLOSS LAMP LO 33
25 POWER
120 VAC
HI 32
26 -15 VDC
BW
HEATER
LO 31
27 SIGNAL SYSTEM
COMMON
HEATED
AIR WIPE
28 +15 VDC
LO 30
SMART PLATFORM
BOTTOM POWER
086086-052, SIDE 2, REV A
Figure 11-7 Sample Diagnostic Card: Bottom Power

The Top Signal card is to be used for diagnostics performed both at the sensor and
the AccuRay Smart Processing Center backplane. Refer to Figure 11-8 on page 255.


1 ASH (Purge)
AccuRay®
20 COMMON DIAGNOSTIC IR LAMP SENSOR 19
2 BW (Purge) GLOSS CLAMP 37
21 HI OPTIPAK CLAMP 18
BW
3 LO 36
22 HI 17
ASH
4 LO OFF 35
AUTO EDGE
23 HI OF SHEET
ON 16
BRIGHTNESS
5 LO ASH 34
ELECTROMETER
24 HI GAP ATC GAP
TEST/CLAMP
BW 15
SENSOR BW
6 LO INTERLOCK SHEET LO 33
HI TEMPERATURE
25 HI 14
GLOSS THERMISTOR 32
7 LO ASH
26 +4.5V BIAS 13
8
LO 31
IR
27 HI CALIPER LOGIC HI 12
AIR
LO BEARING 30
9
CAP 11
28 or ATC COLUMN BW
10 +4.5V BIAS THERMISTOR 29
SMART PLATFORM
TOP SIGNAL
086086-051, SIDE 1, REV A
Figure 11-8 Sample Diagnostic Card: Top Signal


The Bottom Signal card is to be used for diagnostics performed both at the sensor
and the AccuRay Smart Processing Center backplane. Refer to Figure 11-9 and to
Figure 11-10 on page 257 for the Backplane diagnostic card.
1 ASH (Purge) AccuRay®

20 COMMON DIAGNOSTIC 19
2 BW (Purge)
GLOSS CLAMP 37
21 HI (-) OPTIPAK CLAMP 18

CALIPER
PROXIMITER SHUTTER
LO SWITCH 36
3
CURRENT 17
22 HI MONITOR
FORMATION ASH MONITOR
LO 35
4 COMMON
X-RAY H.V.
23 HI MONITOR 16
OPACITY
34
5 LO
24 INTERNAL CAP 15
or ATC COLUMN
BW ALARM
6 +4.5V BIAS THERMISTOR 33
GRID
BW SHUTTER 14
25 HI SWITCH
GLOSS INT. CHECK 32
7 LO SAMPLE
GAIN 13
26 HI OPTIPAK MONITOR
VACUUM LO 31
8 LO
CALIPER SIGNAL
27 HI HI 12
VACUUM/ IR
9 LO THERMISTOR DECREASE 30
GAIN
28 THERMISTOR GAIN 11
ASH +15V
10 +4.5V BIAS INCREASE
GAIN 29
SMART PLATFORM
BOTTOM SIGNAL
086086-051, SIDE 2, REV A
Figure 11-9 Sample Diagnostic Card: Bottom Signal Sensor

AccuRay®
TOP POWER
POWER COMMON
SIGNAL COMMON
LIFT SOLENOID
CALIPER HEAD
OPTIPAK LAMP
IR 120VAC LO
GLOSS LAMP
PRESSURE
120VAC HI
120VAC HI
CALIPER
+12VDC
POWER
POWER
J3 1 2 3 4 5 6 7 8 9 10
J4 1 2 3 4 5 6 7 8 9 10 Figure 11-10 Sample Diagnostic Card: Backplane Power
BW HEATER
ASH HEATER
HEATED
AIR WIPE
IR 120VAC HI
CHASSIS
-12VDC
GLOSS LAMP
RETURN
OPTIPAK LAMP
RETURN
-15VDC
+15VDC
BOTTOM POWER
POWER COMMON
SIGNAL COMMON
BW SHUTTER
GLOSS LAMP
ASH FLAG
120VAC HI
120VAC HI
AIR WIPE
HEATED
+12VDC
POWER
10 9 8 7 6 5 4 3 2 1 J17
10 9 8 7 6 5 4 3 2 1 J18
BW HEATER
ASH HEATER
CALIPER HEAT/
VACUUM/PURGE
CHASSIS
-12VDC
ASH SHUTTER
GLOSS LAMP
RETURN
-15VDC
+15VDC
SMART PLATFORM BACKPLANE POWER 086086-053, SIDE 1, REV A

The Bottom Auxiliary Power card is to be used for diagnostics performed at the
sensor only.
1 ASH +15V AccuRay®

20 -12 VDC VOLTAGE 19
ASH
FILAMENT
SYSTEM RETURN 37
21 +12 VDC
36
22 ASH COMMON
ASH +28V
35
23 ASH -15V 120 VAC

HI 34
24 LO
ASH ASH +28V
H.V. RETURN 33
ADJUST
25 WIPER 120 VAC HI 32
26 -15 VDC
31
SIGNAL
27 COMMON SYSTEM 30
28 +15 VDC
SMART PLATFORM
BOTTOM AUX
(ASH WITH REMOTE J-BOX)
086086-053 SIDE 2, REV
Figure 11-11 Sample Diagnostics Card: Bottom Auxiliary Power


The Detector Module card is to be used for diagnostics performed at the sensor only.
1 +12 VDC AccuRay®

20 Purge Sensor Volts 19
2 -12 VDC (not used) PTC Monitor (Switch) 37
21 ELHV PcBd °C/10 Chassis Ground 18
3 Chassis Ground PTC Monitor (High) 36
22 CAP Thermistor Low 17
4 +15 VDC Chassis Ground 35
23 CAP Thermistor High 16

2
5 -15 VDC GAP Signal Low 34
24 15
Gap Signal High 2

6 Signal Common 33
25 Signal Common ELHV Test (Test=Low) 14
2
7 Gap PcBd °C/10 32
26 13
8 31
27 Electrometer Low 12
9 30
28 Chamber HV/100 Electrometer High 11
2
10 Gap Oscillator 29
(TOP) Detector Module, STLK11, STLP3, STLXR3

2 STLK11 and STLP3 only
Figure 11-12 Sample Diagnostics Card: Detector Module


The Source Module card is to be used for diagnostics performed at the sensor only.
1 +12 VDC AccuRay®

20 Alarm Grid, STLP3 Purge Sensor Volts 19
2
2 -12 VDC PTC Monitor (Switch) 37
21 Chassis Ground 18
3 Chassis Ground PTC Monitor (High) 36
22 CAP Thermistor Low 17
4 Chassis Ground 35
23
CAP Thermistor High 16
5 34
24 NC Shutter Stat (Red) 15
6 33
25 NO Shutter Stat (Grn) 14

2
7 Filament Monitor 32
26 Chk Samp Stat (Future) 13
Ctrl, Shutter 2
8 Monitor Common 31
2 12
27 +5V Ref
Anode Curr. Mon. 2

9 Ctrl, Int Chk Samp 30
28 11
10 2
X-ray HV/1000 29
(BOTTOM) Source Module, STLK11, STLP3, STLXR3

2 STLXR3 only
Figure 11-13 Sample Diagnostics Card: Source Module

Troubleshooting Start-Up Messages
101764-003
Use the following tables to troubleshoot the Smart Platform at startup or after a reset. The tables list the start-up messages
in sequence along with a description of system activities and corrective actions (where appropriate).
Table 11-6 086349-002 MPRC Board
Expected Start-up Console Message Activity Corrective Action

Smart Platform start-up revision IMP 200 001 Prior to messages, the MPRC If the messages never appear
(c) Copyright 1991, ABB Process Automation Inc. is running internal on the screen either the MPRC
diagnostics on the CPU memory diagnostics have failed or
All Rights Reserved

and the HDLC serial the RAM disk area cannot be
interface. The messages are read.
at the beginning of the start-
up file and indicate the first
attempts to read the RAM disk
area.
Troubleshooting
261
262
HDLC Loop back Test (Dev0/ChanB): PASSED These messages are responses The loading process will not
HDLC Loop back Test (Dev0/ChanA): PASSED to diagnostic exercises which halt during these checks but
include a check on the MPRC it will be up to service
BRAM address:0x2000000
microprocessor serial link personnel to go back later and
BRAM size:0x200 (HDLC) and a check on the RAM correct any RAM disk file
Checksum Table:0x207fc00 disk area integrity and errors found. Errors found
BRAM checksumsOK condition. during the HDLC checks will
The fsck repair utility is run probably prevent
for both bram1 and bram2 RAM communications with the
BRAM address 0x2080000 micro-controllers and any
disk areas. The utility
BRAM size:0x9ff response will only be to BRAM errors will prevent the
Checksum table:0x22ff000 report conditions found. libraries from loading.
BRAM ChecksumsOK

/bram1 (NO WRITE)
File System: Volume:
** Phase 1 Check Blocks and Sizes

** Phase 2 Check Pathnames
Troubleshooting
** Phase 3 Check Connectivity

** Phase 4 Check Reference Counts
** Phase 5 Check Free List
46 files 389 blocks 112 free
/bram2 (NO WRITE)


101764-003
101764-003
lib: /lib01/drv/session.lib loaded. btoken[12] AVOS SCNs and special 1. If any AVOS task cannot be
task: /lib01/drv/hdlc loaded. btoken [13], entry[0x14c8c0], stacksize[2048] operating system drivers loaded, it will be noted.
lib: /lib01/lib/libm loaded. btoken [16] are loaded into memory The problem is probably a
lib: /lib01/lib/libsl loaded. btoken [17] from the MPRC PROM area. bad image. Use the last
saved version of the AVOS
lib01 directory.
Using revision file found on: /lib01/avrev, the following diskettes are required: A special utility to check
disk: /lib01/avrev at release av280.5 Avos diskette the revision levels of the 2. If any AVOS library cannot
diskettes from which the be loaded, an “Entering
.
software was loaded, is Migration Mode” message
. will be issued. Use the
run here.
. last saved version of the
. AVOS lib01 directory.
ss280.5 ss01 diskette
Use CTRL-SHIFT |, to get Avos

task: /lib01/drv/slvpmm loaded. btoken [18], entry[0x1834a8], stacksize[2048] prompt. Look at the list of
lib: /lib01/lib/insp_lib loaded. btoken [20] diskettes used to find the
offending diskette. Reload
with the correct diskette.
expanding and loading po_clas.lc The system then starts to If a module cannot be loaded,
• load the various libraries the “Entering Migration Mode”
Troubleshooting
• from the bram2 RAM disk message will be issued.

• area. The final activity Restore the system files from
expanding and loading pm_msdmg.lc
is to load the appl.lib the backup copy.
configuration.
task: /appl/lib/pm_appl.lib loaded. btoken[53], entry[0x23e408], stacksize[4096]
If there are any
application SCNs, they
will be installed at this
time also.
263
264
Smart Platform Application; rev.:@(#)appl_init.m:190.1 The configuration files are Any failure in this process
<<******Application start-up in progress: please wait.******>> read and the system software indicates that one or more
is linked. configuration files are
defective. Restore the last
[1]:APPL_INIT defining exception handlers saved .init files from
[2]:APPL_INIT defining Network Object Dictionary diskette and restart.
[3]:APPL_INIT creating global object collection
[4]:APPL_INIT creating error history
[5]:APPL_INIT creating appl_start community
The system release is: SP280.5 Host communications is set for:

Station ID = 1 Baud Rate = 9600

[01_0]$$
Down-line load Message Banner announcing OK to connect to Host Announcement that the down- Any failure in this process
Computer loaded command from the Host indicates that one or more
computer is ready to be configuration files are
received. Gives conditions defective. Restore the last
for the manual or automatic saved .init files from
Troubleshooting
loading. diskette and restart.

101764-003
Table 11-7 086444-001 MPRC Board
101764-003
Smart Platform start-up revision IMP 200 001 Prior to messages, the MPRC If the messages never appear
(c) Copyright 1991, ABB Process Automation Inc. is running internal on the screen either the MPRC
diagnostics on the CPU memory diagnostics have failed or
All Rights Reserved
and the HDLC serial the RAM disk area cannot be
interface. The messages are read.
at the beginning of the start-
up file and indicate the first
attempts to read the RAM disk
area.

Troubleshooting
265
266
BRAM address 0x2000000 These messages are responses The loading process will not
BRAM size: 0xaff to diagnostic exercises which halt during these checks but
include a check on the MPRC it will be up to service
Checksum table:0x22bf000
microprocessor serial link personnel to go back later and
BRAM Checksums OK. (HDLC) and a check on the RAM correct any RAM disk file
disk area integrity and errors found. Errors found
/bram1 (NO WRITE) condition. during the HDLC checks will
The fsck repair utility is run probably prevent
for both bram1 and bram2 RAM communications with the
disk areas. The utility micro-controllers and any
** Phase 1 Check Blocks and Sizes response will only be to BRAM errors will prevent the
** Phase 2 Check Pathnames report conditions found. libraries from loading.

Troubleshooting
AccuRay Virtual Operating System
(c) Copyright 1991-1998, Process Automation Business, Inc.
/bram1 (NO WRITE)


101764-003
101764-003
All Rights Reserved AVOS SCNs and special 1. If any AVOS task cannot be
lib: /lib01/drv/session.lib loaded. btoken[15] operating system drivers loaded, it will be noted.
task: /lib01/drv/hdlc360 loaded. btoken [16],entry[0x8aff4f4],stacksize [4000] are loaded into memory from The problem is probably a
lib: /lib01/lib/stack.lib loaded. btoken [19] the MPRC PROM area. bad image. Use the last
saved version of the AVOS
lib01 directory.
Using revision file found on: /lib01/avrev, the following diskettes are required: A special utility to check
disk: /lib01/avrev, at release av300_0 Avos diskette the revision levels at the 2. If any AVOS library cannot
diskettes from which the be loaded, an “Entering
disk: /appl/clm/prrev, at release pr300_0 Product diskette
software was loaded,is run Migration Mode” message
disk: /appl/clm/serev, at release se300_0 Sensors diskette will be issued. Use the
here.
disk: /appl/clm/a1rev, at release a1300_0 APPL1 diskette last saved version of the
disk: /appl/clm/a2rev, at release a2300_0 APPL2 diskette AVOS lib01 directory.

Using revision file found on: /lib01/avrev, the following disks are required:
Use CTRL-SHIFT |, to set the
SP300.0 SystemRelease AVOS prompt. Look at the
ac300_0 Ace diskette list of diskettes used to
av300_0 Avos diskette find the offending
h1300_0 Health1 diskette diskette. Reload with the
correct diskette.
Troubleshooting
h2300_0 Health2 diskette

pr300_0 Product diskette
se300_0 Sensors diskette
a1300_0 APPL2 diskette
a2300_0 APPL2 diskette
sa300_0 SCNA diskette
sb300_0 SCNB diskette
ss300_0 SS01 diskette
task: /lib01/drv/ethertsk loaded. btoken[20], entry[0x8b3860c], stacksize[8000]

task: /lib01/bin/sokit2me loaded. btoken[23], entry[0x8b3b5a4], stacksize[10000]
Sokit2me Running...
lib: /lib01/lib/insp_lib loaded. btoken [24]
lib: /lib01/lib/libm loaded. btoken[25]
lib: /lib01/lib/libs1 loaded. btoken[26]
267
268
task: /appl/bin/slvpmm loaded. btoken[28], entry[0x8b45304], stacksize[2048] The system then starts to If a module cannot be
lib: p0_clas.lib loaded. btoken[30] load the various libraries loaded, the “Entering
. from the bram2 RAM disk Migration Mode” message
. area. The final activity will be issued. Restore
. is to load the appl.lib the system files from the
. configuration. backup copy.
.
lib: pm_msdmy.lib loaded. btoken[63]
If there are any
application SCNs, they
task: /appl/lib/p1_appl.lib loaded. btoken[64], entry[0x8c757b4], stacksize[4096]
will be installed at this
time also.
Smart Platform Application; rev.:@(#)appl_init.m 1.12 The configuration files Any failure in this
are read and the system process indicates that one
<<******Application start-up in progress: please wait.******>> software is linked. or more configuration

files are defective.
[1]:APPL_INIT defining exception handlers
Restore the last saved
.init files from diskette
[2]:APPL_INIT defining Network Object Dictionary
and restart.
[3]:APPL_INIT creating global object collection
[4]:APPL_INIT creating error history
[5]:APPL_INIT creating appl_start community
Troubleshooting
THE SYSTEM RELEASE IS: SP300.0

The current system release number has not been stored in: appl.ini---
you may want to gstore: appl.ini!
HOST COMMUNICATIONS IS SET UP FOR: stationID = 1 baudRate = 9600
task: /lib01/bin/swi loaded. btoken[65], entry[0x8c9013c], stacksize[3000]
task: /lib01/bin/asi loaded. btoken[66], entry[0x8c98fec], stacksize[4096]
asiServer: Using nIndex = 0
startdmp: comout_no in use is 4
AVOS Shell 300.1.1.2
[01_0] $$ Announcement that the Any failure in this

down-loaded command from process indicates that one
If the Host is down it will automatically download files to the Smart Platform the Host computer is ready or more configuration
when it is started up. to be received. Gives files are defective.
conditions for the manual Restore the last saved
If the HOST is already up, then request a manual reload of this Smart Platform. or automatic loading. .init files from diskette
and restart.
101764-003

A
Appendix A:
Service Workstation Activities
To modify the Smart Platform performance you will use the Service Workstation.
These are procedures you will need for maintenance of the Smart Platform.
Section............................................................................................... Page
Service Workstation Setup ............................................................................ 270
Displaying Reports ........................................................................................ 271
Utilities .......................................................................................................... 274
Identifying Sensor Configuration .................................................................. 277
Determining Software Release Levels .......................................................... 278
Preparing On–Site Documentation ................................................................ 279
101764-003 Service Workstation Activities 269


Service Workstation Setup

To use the Service Workstation for exercising the Smart Platform you have to have
the following software loaded into the workstation and install a cable between the
workstation and the platform.
Note: For systems manufactured before October 1995, the ASPC

backplane part number is 086345-003. For systems manufactured
after October 1995, the ASPC backplane part number is 086345-
004. For a diagram of the -003 and -004 ASPC backplanes, see
Chapter 1, Product Overview.
Software
Refer to the appropriate AccuRay Smart Platform System Software Manual,
101760-xxx.
Hardware
Connect the custom nine–pin connector from the serial port on the Service
Workstation to the debug port (see Figure A-1) on the Smart Platform.
J2 DRIVE END P3 P4 P5
TOP POWER PROGRAM
J1 TOP SIGNAL
P1
TOP POWER
J3
BOTTOM POWER PROGRAM
P2
J4
TOP SIG
J5 DRIVE END DIAG
J6 SYSTEM SERIALJ7 SERVICE PORT

Service Port for the
Smart Platform
Figure A-1 Debug Port on the Smart Platform (-003 Backplane shown)
270 Service Workstation Activities 101764-003


Displaying Reports
The Service Workstation can be used to view Standardize, Check Sample and
Calibrate Sample reports. These reports contain the same information sent to the
Host computer system but the data is displayed differently.
Standardize Report
There are two report arrays associated with the Standardize results:
stdzResultsPending and stdzResults. stdzResultsPending reports on the results
of the last standardize whether the results are within limits or not. stdzResults
reports the results of the last acceptable standardize.
The procedure for displaying these reports is as follows:
1. Access the inspect utility.
2. Type: betaSensor01->stdzResultsPending (for example)
The system will report back the address of that report.
3. Type in the address of the report.
The system will display the results of the last standardize. See Figure A-2.
I> betaSensor01->stdzResults
stdzResults: 0x307bb2 (int *)
I> 0x307662
0x307bb2 (id)
0x307bb2: ”0X307bb2” (STRUCT_PRIVATE)
ISA: BWStdzRslts (STRUCT_SHARED *)
mySelf: 0x307bb2 (long)
problemList 0x30d72 (id)
tempCompFlag 0 ’\0’ (char)
zeroScaleInput 0.000338776 (double)
zeroScaleInputSigma 7.21414e-09 (double)
lastCleanStdz: 0x307bd0 (char [20])
dirt: 0 (double)
fullScaleTempRef: 55.0098 (double)
fullScaleTempSigma: 1.2531e-09 (double)
logRangeClean: 1.45815 (double)
logVoltageRange: 1.45815 (double)
voltageRange 4.29802 (double)
voltageSigma: 3.70175e-05 (double)
tClean 0 (long)
sourceTemperature 54.8 (double)
detectorTemperature 55.06 (double)
sourcePurge 3.70309 (double)
detectorPurge 3.41578 (double)
Figure A-2 Example of Standardize Report


To view the results of the last acceptable standardize, type in the variable:
stdzResults. When there are no standardize failures, the address of the stdzResults
and stdzResultsPending will be the same. The system will respond with the address
of that report. Type in the address and the system will display the report.
If you want to know when the last clean standardize occurred, type in the address
of the lastCleanStdz and the system will display the date and time of the last clean
standardize.
Sample Check Report
The procedure for displaying the Sample Check report is as follows:
2. Type: betaSensor01->checkSampleResults (example for basis weight)
The system will display the results of the last sample check. See Figure A-3.
|-----------------------------------------------------------------------|
| I> betaSensor01->checkSampleResults |
| checkSampleResults: 0x30842a (int *) |
| I> 0x30842a |
| 0x30842a (id) |
| |
| 0x30842a: “0x30842a” (struct_PRIVATE) |
| isa: BWChkSmRslt (struct_SHARED *) |
| mySelf: 0x30842a (long) |
| problemList: 0x30848a (id) |
| name: 0x26b182 (id) |
| transPPT: 1000.46 (double) |
| mylarWt: -0.0277454 (double) |
| slope: 1 (double) |
| offset: 0 (double) |
| tempCompFlag: 0 ’\0’ (char) |
| tempComp: 0.80165 (double) |
| wtTempComp: 0 (double) |
| processBW: -0.0277454 (double) |
|-----------------------------------------------------------------------|
Figure A-3 Example of Sample Check Report


Calibrate Sample Report

The procedure for displaying the Calibrate Sample report is as follows:
2. Type: betaSensor01->calibrateSampleResults (example for basis weight)
The system will display the results of the last Calibrate Sample. See Figure A-4.
|---------------------------------------------------------------------|
|I> betaSensor01->calibrateSampleResults |
| calibrateSampleResults: 0x312c7a |
|I> 0x312c7a |
| 0x312c7a (id) |
| |
| 0x312c7a: “0x312c7a” (struct_PRIVATE) |
| isa: BWCalSmRslt (struct_SHARED *) |
| mySelf: 0x312c7a (long) |
| problemList: 0x308b22 (id) |
| name: 0x26b182 (id) |
| headPosition: 64 (double) |
| transPPT: 602.285 (double) |
| mylarWt: 29.3038 (double) |
| slope: 1 (double) |
| offset: 0 (double) |
| tempCompFlag: 0 ’\0’ (char) |
| tempComp: 0.802075 (double) |
| wtTempComp: 0 (double) |
| processBW: 29.3038 (double) |
|---------------------------------------------------------------------|
Figure A-4 Example of Calibrate Sample Report


Utilities
AVOS is the operating system for the Smart Platform. The operating system controls
the Smart Platform’s scanning, measurement processing and other computing
resources. AVOS also supports a console interface between the Smart Platform’s
computer hardware and technicians requiring access to the software for setup and
troubleshooting.
This section will describe some of the important utilities and procedures required
to interact with the Smart Platform through the Service Workstation.
The inspect Utility
The inspect utility allows examination and modification of instance variables
contained in the Smart Platform software. To use the inspect utility, it is necessary
to know two things: the name of the object where the variable resides, and the name
of the variable.
The names of the objects which are accessible with the inspect utility are given in
the :global printout. The names of the instance variables residing in any given
object, can be listed by entering the object name while in the inspect utility.
The following procedure illustrates how to run the utility and perform some basic
operations.
1. Place the desired Service Workstation in the inspect utility mode by typing
inspect at the $$ prompt.
The response is as follows if it is the first time inspect has been invoked since
the last Smart Platform restart or if class files need to be reloaded:
inspect - @(#)inspect.c 1.1 - 88/10/05
inspect:reading class files.
I>
During normal operation only the I> prompt will appear. The I> is the line
prompt for the inspect utility.
2. Use the following format to enter the requested instance variable:
To display an entire object list of instance variables:
objectName
To display a single instance variable and its value:
objectName->instanceVariableName
To change an instance variable’s value:
objectName->instanceVariableName=value
To list all available object names:
:global


Where:
objectName is the name of the software object containing the desired instance
variable.
instanceVariableName is the instance variable name to be examined.
Value is the new number to be added. It must be in the same format as defined
in the instance variable list.
3. For repeated display or value entry, simply enter a period (.) and press
RETURN. The previously entered command will be repeated.
The gstore Utility
Modified coldstart instance variables must be stored in their respective .ini files
located in BRAM.
Use the following procedure to store modified instance variables.
1. Make the desired value changes to the coldstart instance variables using the
inspect or genrpt utilities.
2. Make a disk copy of all the existing .ini files in the /clm directory using the
backup procedure.
This puts each .ini file onto diskette where it can be retrieved if something goes
wrong with the subsequent gstore command later in this procedure.
3. After all the changes have been made, write the information to the BRAM using
the gstore utility in the AVOS shell at the $$ prompt:
gstore
The utility responds with a menu selection, see Figure A-5. Use Table A-1 on
page 276 to help make a selection. Answer all the interactive messages as
required.
When a selection has been made, the utility will offer the opportunity to
overwrite the existing file, write to a new file, or quit without saving the file.
$$ gstore
Object Graph Storing Utility (imp200.002~)

Selection Object Graph Head of Graph
~~~~~~~~~ ~~~~~~~~~~~~ ~~~~~~~~~~~~~
1 frame (scanner01)
2 frameHI (fhi01)
3 io (ucHardware)
4 pmm (pmmInterface)
ENTER selection or q to quit:
Figure A-5 gstore Menu Screen


Table A-1 gstore Menu Item Descriptions

Selection Object Head of Graph Function
Graph (This section is not part of the
actual menu)
1 frame (scanner01) All coldstart variables associated
with the Smart Platform scanning
and sensors
2 frameHI (fhi01) All coldstart variables associated
with the push button assignments
on the Smart Platform control panel
3 io (VmeHardware) All coldstart variables associated
with the analog and digital I/O
4 pmm pmmInterface All coldstart variables associated
with the Host interface objects
Note: Object Graph refers to the file_name. Head of Graph refers to the
object_name.


Identifying Sensor Configuration

To examine the current configuration of a scanner, follow the steps below.
1. At the $$ prompt type inspect.
2. At the I> prompt type:
( ) [scanner01 print] for the frame community
or ( ) [pmmInterface01 print] for the pmm community.
3. You will receive a printout. See the examples below.
The Scanner01 printout contains the following information.
Example: scanner01 (Scanner1180M) : with AEOS
sheetBrkDet01 (SheetBrkDet)
Servo01 (Servo)
head01 (Head)
Real Sensors:
BetaSensor01 (BetaSensor):with ATC
IRSensor01 (IRSensor) : Type HEMI+
Derived Sensors:
CondWtSensor01 (CondWtSensor)
Sensors Not In Operation:
(any sensors which are asleep)
The pmmInterface0x printout contains the following information.
Example: pmmInterface (PmmInterface)
pmmDriver (PmmDriver):
pmmFrames:
pmmFrame01 (Pmm Frame)
pmmSensors:
pmmBeta01 (Pmm Beta)
pmmCondWt01 (pmmCondWt)
pmmIRSensor01 (pmmIRSensor)


Determining Software Release Levels

The Smart Platform software is controlled by a release level mechanism. This
mechanism makes maintenance control and site software identification possible.
Each major area of the system contains an image which reveals the release level of
that component. The major areas are:
• Application software
• Microcontroller software
• Lib01 library software
• AVOS software
The following procedure will result in a report which identifies the release level of
each major area.
1. Type the following command while in the AVOS ($$) shell:
. /ss01/clm/revid
2. The system will respond with a report. See the following example.
revision level of LIB01 libraries

/lib01/lib01rev:
lib01_rev.c300.070Copyright 1993–1994 ABB Industrial Systems Inc.
revision level of the micro–controller software

smi_id.c 140.0 04/26/95 (c) Copyright 1991-1994
what: Cannot open /appl/smi/ecc.b
revision level of the application libraries
/appl/lib/p1_scan.lc:
Scanner.m140.1
revision level of AVOS software
@(#)avos_rev.c 300.005


Preparing On–Site Documentation

Each time the Smart Platform subsystem is restarted, it dynamically recreates the
various objects and their linkages. As a result, the absolute address of any object
and their associated instance variables can change from startup to startup.
Therefore, access to the various instance variables and objects is primarily done
through ASCII names and tokens. These are used as arguments to the utility
commands which in turn gives access to the data in memory.
It is important to have available the lists of names and token numbers which are
recognizable within the subsystem. This section identifies the activities which must
be done to obtain these name and token lists. In some cases, the list should be
printed out each time the system is upgraded. This will insure that certain address
locations can be accessed for troubleshooting purposes in case of processor halts.
See Table A-2.
Table A-2 Hardcopy Reports for On–Site Documentation
Report Utility Command Printout Purpose
Name Frequency
System dproc First startup Gives a list of all of the
Processor Run processes that are
List running
Sub-System .∆/ss01/clm/revid First startup Gives a list of the release
Release levels within the system
Levels
Module Map map -m Each upgrade Provides the name, type,
and stack size of each
module in the order in
which it was loaded
inspect inspect First startup Provides a list of module
Utility Object :global names which will be
Names recognized by the
inspect utility
Table A-2 (Continued on next page)


Table A–2 (continued)

Report Utility Command Printout Purpose
Name Frequency
Scanner and inspect After Provides a
Sensor <each object> calibration, complete list of
Instance (see partial list below) tuning, and the instance
Variable List scanner01 setup for each variables, their
betaSensor01 scanner and names and
IRSensor01 sensor has current values, as
caliperSensor01 been a record of setup
ashSensor01 completed or and calibration
optipakSensor01 changed activity
pmmFrame01
I\O ()[ucHardware printOnConsole] First startup Provides a list of
Configuration all of the analog
and digital I/O
and their channel
assignments on
one report


Index
Symbols ASPC Location, 32

At the Host Computer, 162, 164, 165
+/- 12 Volt Fuses, 6 At the Platform, 165
At the Service Workstation, 162, 164, 165
A Attaching the Platform to the Pedestals, 38
Automatic Edge-of-Sheet, 102
A Board Temperature is Out of Limits, 238 Automatic Startup, 181
Acceptable Range for Standardize Limits, 149
AccuRay Smart Processing Center (ASPC)
Backplane Identification, 4 B
Air and Water Supply, 59 Background, 155
Air Column Measurement (Smart Basis Weight Basic Tuning, 83
Sensor Only), 129 Basis Weight Sensor, 127
Air Gap Alignment, 52 Basis Weight Sensor Setup, 112
Air Profile Compensation for Basis Weight, Gloss, Beam Air Flow Off, 240
and Caliper, 161 Blower Location, 33
Air Profile Compensation for OptiPak, 164
Air Profile Data Collection, 161
Air Purge, 58 C
Air Purge Filter Inspection, 197 Cabinet Environmental Checks, 202
Air Temperature Compensation for Basis Weight, Cabling, 31
157 Calibrate Sample (Sample Cut), 174
Al Slope and Offset Calc Failed, 241 Calibrate Sample Report, 273
Alarm Messages, 238 Caliper Sensor, 139, 148, 152
Alarms and Fault Reporting, 78 Caliper Sensor Setup, 114
Alignment of the Customer Pedestals, 36 Carriage Alignment, 45
Apparent Density, 125 Carriage Drive Belt, 206
Apparent Density Setup, 114 Carriage Wheel, 203
Appendix A Changing Caliper Output Units, 125
Service Workstation Activities, 269 Changing Ream Size, 124
determining software release levels, 278 Changing the Motion Restriction Sensitivity, 107
displaying reports, 271 Changing the Standardize Mode of the FCP
calibrate sample report, 273 Standardize Request, 145
sample check report, 272 Checklist, 24
standardize report, 271 Chiller Flow Out of Limits, 238
Cleaning the Air Purge Filter, 198
identifying sensor configuration, 277
Cleaning the Compressed Air Filter, 199
preparing on-site documentation, 279
Control Panel Description, 170
Service Workstation setup, 270
Control Panel Functions, 72, 173
hardware, 270
Control Panel Operation, 169
software, 270 control panel description, 170
utilities, 274 control panel functions, 173
the gstore utility, 275 calibrate sample (sample cut), 174
the inspect utility, 274 jog, 173
Ash Sensor, 151 local, 173
Ash Sensor Setup, 113 off-sheet, 173
Ash Units Setup, 126 on-sheet, 173
101764-003 Index 281


Control Panel Operation (Continued) Entering AEOS Setup Parameters, 104
remote, 173 Environmental Data, 30
sample check, 174 Equipment Location, 32
scan limit set, 176 Error Conditions, 138
self test, 175
standardize, 174
head split switches, 177
F
Smart Platform modes of operation, 171 Fine Tuning ATC with dBWDT, 159
local, 171 Flex Cable, 215
local/head split, 172 Flex Cable Replacements, 220
remote/off-sheet, 171 Flex Power Cable Retrofit Kit, 220
remote/on-sheet, 171 Frame Health Report, 240
Controlling the Type of Standardize for a Specific
Sensor, 146
Current Far Scan Position (KFEOS), 92
G
Current Home Scan Position (KHEOS), 91 Garage Position (OFF), 91
General Description, 72
General Information, 141
D Gloss Sensor, 136, 154
Data Collection, 165 Gloss Sensor Head Constant Tuning, 137
DC Voltage Level Checks, 202 Gloss Sensor Setup, 113
Default Single Point Position (SPPOS), 91 Grounding, 30
Definition of Head Package Dimensions, 96
Determining and Entering the Head Dimensions, 99
Determining Software Release Levels, 278
H
Diagnostic Card Operation, 249 Handling Instructions, 25
Diagnostic Cards, 252 Handling the Source, 18
Diagnostics Performed at the Sensor, 250 Hardware, 270
Digital Input Invert Adjustment for the Smoothness Hardware Installation, 23
Sensor, 166 attaching the platform to the pedestals, 38
Dimensions and Weight, 27 carriage alignment, 45
Displaying Reports, 271 handling instructions, 25
Downloading Parameters, 76 dimensions and weight, 27
Drive Belt Tension and Tip Adjustment, 189 space requirements, 27
Drive Belt Tension Measurement, 188 installation requirements, 30
Drive Motor Adjustment, 190 cabling, 31
Drive Motor Belt, 204 electrical supply and grounding
Drive Motor Belt Inspection, 190 requirements, 30
Drive Motor Controller (Fincor and Lovejoy), 223 grounding, 30
Drive System, 9 Smart Platform distribution center
(SPDC), 31
E supply, 30
environmental data, 30
ECF and ECS LEDs, 243
equipment location, 32
Electric Chassis, 218
Electric Chassis Replacement Procedure, 218 ASPC location, 32
Electrical and Cable Systems, 10 blower location, 33
Electrical Hook-Up, 61 Smart Platform Power Distribution
Electrical Supply and Grounding Requirements, 30 Center (SPDC), 33
Electronics Health Report, 238 equipment locations
Enabling Air Profile Compensation, 163 operator control panel location, 33
Encoder, 226 liquid cooling unit setup, 34
End Column Power Temp Out of Limits, 238 pass angle alignment, 46
Enter Calibration Head Constants, 127
282 Index 101764-003


Hardware Installation (Continued) LOCAL/REMOTE, 75
air gap alignment, 52
process direction alignment, 49
pedestal installation and alignment, 35
M
alignment of the customer pedestals, 36 Machine, 29
installation guidelines, 35 Maintenance Procedures, 183
platform alignment, 43 air purge filter inspection, 197
safety, 28 cleaning the air purge filter, 198
machine, 29 purge blower replacement process, 197
personnel, 28 inspecting the compressed air filters, 199
scan direction alignment, 54 cleaning the compressed air filter, 199
unpacking instructions, 24 inspecting the drive system, 187
checklist, 24 drive belt tension and tip adjustment, 189
verify air gap, 53 drive belt tension measurement, 188
Head Package Dimensions Setup, 96 drive motor adjustment, 190
Head Position Setup, 91 drive motor belt inspection, 190
Head Position Verify Outside Limits, 240 head separation and limit switch
Head Position Verify Test - Timeout, 240 inspection, 193
Head Resynchronize - Timeout, 240 seal belt tension adjustment, 192
Head Separation and Limit Switch Inspection, 193 seal belt tension inspection, 191
Head Speed Inconsistency, 240 inspecting the incoming power, 186
Head Split Switches, 177 inspecting the water filter, 200
Health Page Standardize Reports, 145 platform alignment inspection, 196
power and temperature checks, 201
cabinet environmental checks, 202
I DC voltage level checks, 202
Identifying Different Backplanes, 4 Smart Platform maintenance logs, 184
Identifying Sensor Configuration, 277 wheel inspection, 195
Idler Pulley, 208 Manual Startup, 180
Implementation of the Sensor Verification Program, Maximum Far Measure Position (LFEOS), 92
156 Measurement Setup, 111
Individual Responsibility, 20 air profile compensation for basis weight, gloss,
Inspecting the Compressed Air Filters, 199 and caliper, 161
Inspecting the Drive System, 187 air profile data collection, 161
Inspecting the Incoming Power, 186 at the Host computer, 162
Inspecting the Water Filter, 200 at the Service Workstation, 162
Installation Guidelines, 35 enabling air profile compensation, 163
Installation of the Source, 19 air profile compensation for OptiPak, 164
Installation Requirements, 30 data collection, 165
Introduction, 4 at the host computer, 165
IR CoatWeight Sensor Setup, 115 at the platform, 165
IR Moisture Sensor, 131, 150
at the Service Workstation, 165
IR Moisture Sensor Setup, 112
setup, 164
at the Host computer, 164
J at the Service Workstation, 164
Jog, 173 using the data, 165
at the Service Workstation, 165
L air temperature compensation for basis weight,
157
LED Interpretation, 242 fine tuning ATC with dBWDT, 159
Liquid Cooling Unit Setup, 34 verification of setup and stability, 157
Local, 171, 173 digital input invert adjustment for the
Local/Head Split, 172 smoothness sensor, 166
101764-003 Index 283


Measurement Setup (Continued) Measurement Setup (Continued)
enter calibration head constants, 127 the selection of CLEAN or DIRTY
air column measurement (Smart basis standardize modes, 142
weight sensor only), 129 time interval between standardizes,
basis weight sensor, 127 141
caliper sensor, 139 procedure for changing standardize limits,
gloss sensor, 136 141
gloss sensor head constant tuning, 137 Smart basis weight sensors, 147
error conditions, 138 temperature controller setup for basis weight,
IR moisture sensor, 131 ash, and caliper sensors, 118
microwave moisture sensor, 140 Smart ash and Smart basis weight, 120
operation of the sensor Health Pages, 116 temperature controller tuning parameters,
setup checklists, 112 122
apparent density setup, 114 using the optional temperature controller
ash sensor setup, 113 utility, 123
basis weight sensor setup, 112 verification, 155
caliper sensor setup, 114 background, 155
gloss sensor setup, 113 implementation of the sensor verification
IR CoatWeight sensor setup, 115 program, 156
IR moisture sensor setup, 112 phase I - initial static verification, 155
microwave sensor setup, 115 phase II - process measurement
OptiPak sensor setup, 113 verification, 155
sheet temperature sensor setup, 114 phase III - continuing certification, 155
Smart Color sensor setup, 115 Mechanical Structure, 7
smoothness sensor setup, 115 Microwave Moisture Sensor, 140
setup of customer units, 124 Microwave Sensor Setup, 115
apparent density, 125 Minimum Home Measure Position (LHEOS), 91
ash units setup, 126 Motion Restriction Sensitivity, 106
changing caliper output units, 125 Motor Controller Setup, 79
ream size, 124 Motor Controller Temp Out of Limits, 240
changing ream size, 124 Motor Drive Parameters, 73
standardize limits, 141 Motor Drive Replacement, 222
acceptable range for standardize limits, Motor Drive Setup (ABB ACS-100), 72
149 Motor Stopped by Obstacle, 240
ash sensor, 151 Moving Around the Menu, 75
caliper sensor, 152 MPRC LEDs, 244
gloss sensor, 154
IR moisture sensor, 150 N
OptiPak sensor, 151 Notes about LHEOS and LFEOS (Scanning
caliper sensor, 148 Measurement Limits), 94
changing the standardize mode of the FCP
standardize request, 145
controlling the type of standardize for a O
specific sensor, 146 Off-Sheet, 173
general information, 141 On-Sheet, 173
health page standardize reports, 145 Operation of the Sensor Health Pages, 116
reporting of "internal" check sample Operation Overview, 109
Operator Control Panel Location, 33
during standardize, 145
OptiPak Sensor, 151
standardize delay after long off-sheet OptiPak Sensor Setup, 113
periods, 144 Other Host Setup Procedures, 110
284 Index 101764-003


P Platform Tuning (Continued)

other host setup procedures, 110
Panel Operations, 75 platform software setup checklist, 70
Pass Angle Adjustment, 46 standardize off-sheet delay setup, 108
Pedestal Installation and Alignment, 35 operation overview, 109
Personnel, 28 setup procedure, 108
Phase I - Initial Static Verification, 155 Power and Temperature Checks, 201
Phase II - Process Measurement Verification, 155 Power Down and DC Power Analysis, 246
Phase III - Continuing Certification, 155 Power Shelf Temperature Out of Limits, 240
Platform Alignment, 43 Power Supply LEDs, 242
Platform Alignment Inspection, 196 Preparing On-Site Documentation, 279
Platform Software Setup Checklist, 70 Pressure Switch, 225
Platform Tuning, 69 Print Books, 6
automatic edge-of-sheet, 102 Procedure, 79, 83, 104
entering AEOS setup parameters, 104 Procedure for Changing Standardize Limits, 141
procedure, 104 Procedure for Determining Position Values, 95
setup guidelines, 103 Procedure for LHEOS and LFEOS, 94
basic tuning, 83 Process Direction Alignment, 49
procedure, 83 Product Overview, 1
changing the motion restriction sensitivity, 107 AccuRay Smart Processing Center (ASPC)
head package dimensions setup, 96 backplane identification, 4
definition of head package dimensions, 96 +/- 12 volt fuses, 6
determining and entering the head identifying different backplanes, 4
dimensions, 99 introduction, 4
head position setup, 91 print books, 6
current far scan position (KFEOS), 92 slot assignments, 5
current home scan position (KHEOS), 91 drive system, 9
default single point position (SPPOS), 91 electrical and cable systems, 10
garage position (OFF), 91 mechanical structure, 7
maximum far measure position (LFEOS), way system, 8
92 service tools, 13
minimum home measure position Service Workstation, 12
(LHEOS), 91 Smart Platform 1200 options, 3
notes about LHEOS and LFEOS (scanning scanner options, 3
measurement limits), 94 sensor options, 3
procedure for LHEOS and LFEOS, 94 Purge Blower Replacement Process, 197
procedure for determining position values,
95
standardize position (STDZ), 91
R
motion restriction sensitivity, 106 Radiological Safety, 15
motor controller setup, 79 handling the source, 18
procedure, 79 individual responsibility, 20
motor drive setup (ABB ACS-100), 72 installation of the source, 19
control panel functions, 72 safety features, 16
general description, 72 Ream Size, 124
motor drive parameters, 73 Remote, 173
panel operations, 75 Remote/Off-Sheet, 171
alarms and fault reporting, 78 Remote/On-Sheet, 171
Replacement Parts for the ASPC, 230
downloading parameters, 76
Replacement Parts List, 227
LOCAL/REMOTE, 75 Replacement Procedures, 203
moving around the menu, 75 carriage drive belt, 206
setting a parameter value, 75 carriage wheel, 203
uploading parameters, 77 drive motor belt, 204
101764-003 Index 285


Replacement Procedures (Continued) Smart Platform Power Distribution Center (SPDC),
drive motor controller (Fincor and Lovejoy), 33
223 Smoothness Sensor Setup, 115
electric chassis, 218 Software, 270
electric chassis replacement procedure, SP1200 Power Up Procedure, 63
218 Space Requirements, 27
flex cable replacements, 220 Split Rollers, 213
flex power cable retrofit kit, 220 Standardize, 174
encoder, 226 Standardize Delay After Long Off-Sheet Periods,
flex cable, 215 144
idler pulley, 208 Standardize Limits, 141
motor drive replacement, 222 Standardize Off-Sheet Delay Setup, 108
pressure switch, 225 Standardize Position (STDZ), 91
replacement parts for the ASPC, 230 Standardize Report, 271
replacement parts list, 227 Starting Up the Software, 67
seal belt, 210 Startup Options, 179
split rollers, 213 automatic startup, 181
Reporting of "Internal" Check Sample During manual startup, 180
Standardize, 145 Service Workstation software startup, 182
Supply, 30
S
Safety, 28 T
Safety Features, 16 Temperature Controller Setup for Basis Weight,
Sample Check, 174 Ash, and Caliper Sensors, 118
Sample Check Report, 272 Temperature Controller Tuning Parameters, 122
Scan Direction Alignment, 54 The gstore Utility, 275
Scan Limit Set, 176 The inspect Utility, 274
Scanner Options, 3 The Selection of CLEAN or DIRTY Standardize
Seal Belt, 210 Modes, 142
Seal Belt Tension Adjustment, 192 Time Interval Between Standardizes, 141
Seal Belt Tension Inspection, 191 Troubleshooting, 237
Self Test, 175 alarm messages, 238
Sensor Options, 3 electronics health report, 238
Service Tools, 13 a board temperature is out of limits,
Service Workstation, 12 238
Service Workstation Setup, 270
chiller flow out of limits, 238
Service Workstation Software Startup, 182
Setting a Parameters Value, 75 end column power temp out of limits,
Setup, 164 238
Setup Checklists, 112 frame health report, 240
Setup Guidelines, 103 Al slope and offset calc failed, 241
Setup of Customer Units, 124 beam air flow off, 240
Setup Procedure, 108 head position verify outside limits,
Sheet Temperature Sensor Setup, 114
240
Slot Assignments, 5
Smart Ash and Smart Basis Weight, 120 head position verify test - timeout,
Smart Basis Weight Sensors, 147 240
Smart Color Sensor Setup, 115 head resynchronize - timeout, 240
Smart Platform 1200 Options, 3 head speed inconsistency, 240
Smart Platform Distribution Center (SPDC), 31 motor controller temp out of limits,
Smart Platform Maintenance Logs, 184
240
Smart Platform Modes of Operation, 171
motor stopped by obstacle, 240
286 Index 101764-003


Troubleshooting (Continued) Using the Data, 165
power shelf temperature out of limits, Using the Optional Temperature Controlller Utility,
240 123
undefined alarm, 241 Utilities, 274
voltage level out of limits, 239 Utility Service Installation, 57
undefined alarm, 239 air and water supply, 59
diagnostic card operation, 249 air purge, 58
diagnostic cards, 252 electrical hook-up, 61
diagnostics performed at the sensor, 250 SP1200 power up procedure, 63
LED interpretation, 242 starting up the software, 67
ECF and ECS LEDs, 243
MPRC LEDs, 244 V
power supply LEDs, 242
Verification, 155
power down and DC power analysis, 246
Verification of Setup and Stability, 157
troubleshooting start-up messages, 261
Verify Air Gap, 53
Troubleshooting Start-Up Messages, 261
Voltage Level Out of Limits, 239
U W
Undefined Alarm, 239, 241
Way System, 8
Unpacking Instructions, 24
Wheel Inspection, 195
Uploading Parameters, 77
101764-003 Index 287

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101764-003 Smart Platform 1200 Installation & Maintenance Manual

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Smart Platform TM 1200

© 1992, 1993, 1996, 1997, 1998 by ABB Industrial Systems Inc.

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Document Version History

Version Effective Sections Changed Sections Added Sections Deleted

J July 1998 Entire Manual

101764-003 Document Version History

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For ABB Employee Use Only

Caution and Warning Symbols

General Meaning of Safety Colors

1. Blue is considered a safety color only if used in a circular shape.

101764-003 Warning iii

For ABB Employee Use Only

Definition of Cautions and Warning Symbols

This symbol warns of dangerous voltage. This symbol

This is a radiation warning and is used when ionizing

This is a general warning symbol and is to be used if

This symbol warns of potential electrostatic

This symbol warns of a potential crushing hazard.

This symbol warns of a potential hand or

For ABB Employee Use Only

This symbol warns that equipment may

This symbol is a reminder that the motor must be

This symbol is a reminder that it is mandatory to

See WARNING text.

Exposed moving parts can

This symbol indicates the maximum

For ABB Employee Use Only

101764-003 Table of Contents vii

For ABB Employee Use Only

viii Table of Contents 101764-003

For ABB Employee Use Only

101764-003 Table of Contents ix

For ABB Employee Use Only

x Table of Contents 101764-003

For ABB Employee Use Only

9 Maintenance Procedures..................................................... 183

101764-003 Table of Contents xi

For ABB Employee Use Only

xii Table of Contents 101764-003

For ABB Employee Use Only

Figure 1-1 System Overview .................................................................. 2

101764-003 List of Figures xiii

For ABB Employee Use Only

Figure 5-1 Menu Tree ............................................................................. 71

xiv List of Figures 101764-003

For ABB Employee Use Only

Figure 7-1 The Smart Platform Control Panel ........................................ 170

101764-003 List of Figures xv

For ABB Employee Use Only

Figure 11-5 Basis Weight Detector Module ............................................. 251

xvi List of Figures 101764-003

For ABB Employee Use Only

101764-003 Product Overview 1

For ABB Employee Use Only

Smart Platform 1200

Host Computer System

Figure 1-1 System Overview

2 Product Overview 101764-003

For ABB Employee Use Only

Smart Platform 1200 Options